Sr. Process Development Engineer Resume Example
Chemical / Innovative Process Engineer with +25 years of experience managing projects from concept to completion. I have a natural talent for designing and building new processes and for identifying existing process weaknesses and implementing cost effective improvements. I work well within a team and take time to collaborate with other departments from manufacturing to operations and marketing. .
Automation Control Design Proficient in AutoCAD, SAP, Minitab, and Microsoft Office Suite PC Based National Instruments Programming Real Time Data Acquisition System implementation Process Modeling |
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Recent accomplishment include the installation of three "scaled up" Precious Metal Thermal Treatment systems and the implementation of automated slurry milling systems to existing production mills.
•Precious Metal Thermal Treatment
-Project lead on the installation of pilot scale unit.
-Responsible for the design, construction, and budget of lab scale system. Project on time and under budget.
-Subject matter expert during the building and commissioning of production units worldwide.
•Technology transfer
-Commissioning of new plants
-Participated in transfer of new and existing technologies to a manufacturing site.
-Presenter and attendee of global process development meetings, symposium and seminars.
•Automated Slurry Batching
-Lead activity of taking an existing concept, refined engineering details, vendor tested and design confirmed.
-Subject matter expert during the commissioning and installed for the production system
•Automated Slurry Milling
-Developed, built and commissioned scalable prototype mill.
-Proved concept on numerous slurry technologies
-Developed scale up relationship to existing Production Mills.
-Production mill modified and overall concept verified.
-Batch to batch repeatability increases downstream coating efficiency which improves quality and eliminates precious metal loss.
•On-line Calciner for Catalyst Part
-Developed, built and commissioned a prototype unit.
-Unit increases through put by 10-40%
-Reduces resources required by 40%
-Total estimated potential savings of +$10^6 /year (excluding PM savings).
- Manufacturer of Manganese and Vanadium Cathode Powders for Lithium Batteries. Production site in Soda Springs, Idaho.
- Started up and optimized Counter Current Spray Dryer. Improvement over solid state Pre-Mix mixing methods resulted in 10% battery cell capacity increase. Unit was transferred to Idaho to be used as interim production unit.
- DOE with Production Dense Phase Jet Mill resulted in implementation of process for milling 60 to 70 micron beads in Spray Dried Pre-mix to 0.5 microns..
- Identified new Li Analytical Instrument for eliminating scrap and rework. Method used is post product 6 to 8 hour TGA testing.
- Implemented SPC on Jet Mill and Classifier. Includes identifying mill process capability (UCL and LCL's), Gage R&R on measurement method, RS View Data Screens, and Operator Training. Decreased DPM from 450,000 to 40,000. Cp = Cpk.
- Managerial duties for two Exempt Chemists. Include performance evaluations, scheduling, objectives setting, training, and mentoring..
- Lab to Production Process scale-up design for new Motor Cycle Catalyst. Six Sigma methods employed as part of method to ensure a robust design and flawless PPAP.
- Ground floor installation and start up of High Energy continuous media mills. New mills part of catalyst Precious Metal Add facility for new generation catalyst technologies. Base metal slurries contain various mixed metal oxides including transitional aluminas.
- Worked with Mill manufacturer and project engineering to semi automate mill startup operation using PC based control software tied in with plant servers. Mill start up and interlock control improvements resulted in ten fold increase in $10,000 seal life.
- Completed Six Sigma Green belt project; Particle Size Measurement accuracy. Malvern and Beckman Coulter Gage R&R, DOEs for optimum operating procedure completed. Results implemented in production.
- Process Engineer for Precision Metal Catalyst Substrate Coater Team. New design accurately controlled precious metal laden wash coat delivery and eliminated costly recycle wash coat recycle loop. Precious metals Pt, Rh, and Pd control increased from +/- 5% to +/1 %.
- Coaters and Mill systems included RS View HMI software.
- New Chrome-Free Anti-Corrosion Pigment - providing expertise and resources in commercialization of this new wet chemistry product; includes formulation tweaking; new process methods evaluation; Q panel preparation and evaluation as compared to Halox and Strontium Chromate standards.
- Sub-micron milling and spray drying of new Infrared Reflecting Pigments, Yttrium Manganate, Praseodymium Manganate, and Bismuth Manganate. Pilot scale Netzsch Zeta media mill and pilot scale counter-current high pressure fountain type Niro Spray Dryer tested and installed. Spray dried powder 100% above 10 microns to meet EPA PM10 & TSCA Regulations.
- Evaluating sub-micron milling technology for increasing pigment strength in conventional chemistries.
- Single Rotating Hearth furnace Design Project. Successfully produced sticky Antimony-Chrome Titanate metal oxide pigment in saggerless electric furnace. Designed, installed, and optimized.
- Tunnel Kiln Automation Project Team, responsible for sagger filling, loading, and dumping design. Team finalized scope and worked w/ engineering firm to build +/- 10% Capital Appropriation Request.
- Graduate of Degussa International Management Training Program - Training in Spain-Germany-Italy-Japan-Netherlands Degussa Headquarters in Hanau Germany.
- Successfully qualified modified Netszch Bead Mill system for dispersing and filtering high viscosity Plasma Display Paste enamels for electronics market (developed pilot unit in Sakuba, Japan).
- New High Speed Dispersion and emulsifying equipment process for enamel paste mediums manufacture; Ross Emulsifiers.
- Depositor upgrade study for thermoplastic frit enamel bottle coatings
- Acid gas and sub-micron particulate scrubber for Tunnel and Shuttle Kilns. High Pressure drop Venturi Scrubber; Kimre Sub-micron Scrubber, Lime Precoat Dry Bag House Scrubber.
- Bulk Bag handling equipment design for sticky raw materials and products; study published in issue of "Ceramics".
- Bead Mill grinding study for tighter particle size distribution of stains and pigments. Submicron grinding techniques used later in IRR pigments.
- Zircon Attritor improvements and SPC implementation to unit in Puebla, Mexico
- Process design engineer and then Project Manager for $3 million Carbon Impregnation Facility (final product used in Gas Mask Applications) - assumed responsibility for project when project engineer retired. Included $800,000 APV Crepaco Water Scrubber & Ammonia Distillation Tower. Recycled 12 wt. % ammonia solution used again as raw material in solution process.
- Solution of Ammonia soluble zinc, silver, copper, chrome and other metals impregnated onto activated granulated carbon. Equipment included tank farm, fluid bed dryer, bag house, ammonia water scrubber and ammonia recovery distillation tower, raw and finished material handling, fire control systems, electrical controls, transformer and switch gear upgrade, new well pump installations, evaporative cooling tower, foundations, etc.
- Mass flow project in Catlettsburg, KY- Improve mass flow characteristics from granulated carbon bins improving product quality of impregnated product- Installed Matcon discharger flow aids.
- Responsible for activated carbon pellet processing area of plant. Included Kahl mills, rotary tube bakers, package boiler, bag houses, fluid bed dryer, multiple hearth furnace, steam systems, and material handling conveyors and feeders.
- Capital Improvement project for screening room dust collector.
- Installation of moisturizer process for cigarette carbon. Implemented SPC on the process and improved continuous product quality.
- Optimized lime fines Briquette Presses
- SPC Engineer for Direct Coal Fired Rotary Lime Kilns; BOF lime used by Steel Industry
- Designed alternate combustion fuel system for burning hazardous waste oils in cement kiln.
- Radiation Safety Officer for Cesium isotope slurry density meters.
Project Mangement
Laboratory Instrumentation
Mathematical Modeling
Heat Transfer
Furnace Design
Distillation and Acid Gas Scrubber Design
Powder Dosing and Material Handling
Liquid/Solid Separation
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Resume Overview
School Attended
- Youngstown State University
Job Titles Held:
- Sr. Process Development Engineer
- Sr Process Development Engineer / Technician Supervisor
- Advanced Development Process Engineer - Washcoat Milling Subject Matter Expert/Coater Launch Center; Senior Process Engineer
- Sr. Process Engineer
- Process/Project Engineer
- Process Engineer
- Chemical Engineer
Degrees
- Bachelor of Engineering : Chemical, Nuclear Engineering 1987
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