PROFILE: Experience in Unit Op'ns Design of Process Plants

All Unit Operations
From 2003 to 2005 taught “Process Analysis & Synthesis” course plus “Process Design” project to Junior and Senior year undergraduate students in the Chemical and Materials Engineering degree at University of Auckland. These two integrating courses built upon all of the standard unit operations courses content, such as distillation, heat transfer, adsorption and absorption, filtration, fluid transfer, freezing and drying, size reduction, reactors, bulk handling, ion exchange and storage systems. These were applied to mini-FEED design projects for industries relevant to N.Z. e.g. oil refinery, methanol and ammonia plants, dairy processing, cement works, steel plant, distillery, alumina processing.

Below are examples of career projects where Bob had a lead role in design of a specific unit operation.

Distillation
In order to process a wider gravity range of crude oils for three refinery topping units. did process simulation with maximum heat integration, added pumparound circuits and split overhead condensers. Did valve tray selection, procurement and installation. Reviewed licensor designs for azeotropic separation in a petrochemicals plant.

Heat Exchange
In a smaller engineering firm, had direct responsibility for selection of TEMA type and running HTRI software in order to size/rate heat exchangers. At N.Z. SynFuel oversaw modifications to cryogenic equipment in an air separation unit to achieve enhanced nitrogen purity. With my Materials Engineering background, had an ongoing role in EPC firms on the selection of metallurgy for vessel cladding and exchanger tubes.

On several refinery revamp projects, had the responsibility of selecting available used equipment for new purpose, evaluating DP/DT conditions, maximum operating conditions and overpressure protection. Recently met with HTRI to preview upcoming Xchanger Suite 6’s capability of direct integration with HYSIS, PRO/II, ASPEN.

Compression
Integrally involved with RAM (Reliability, Availability, Maintainability) "N+" decision about large pipeline compressor(s) and power generation for an onshore oil & gas system, plus subsequent detailed P&ID review of compressor and support systems

Filtration

• Developed the complete design for a plate-and-frame dewaxing filter system for a lube unit
• Oversaw redesign of large rotating solvent/wax filter to drastically reduce solvent emissions.

Scrubbing

• Process design and materials evaluation (duplex alloy  vs. fiberglass) for SO2 scrubbing system
• Modification of nozzle spray system to manage grinding dust agglomeration in ore milling system.

Reactors

• Debottlenecking twin steam/gas reformers by modifying feed composition, burner flame length.
• Detailed P&ID design through IFD for world’s largest Hydrocracker, and kerosene Hydrotreater.

Storage

• Process and equipment design for refrigerated butadiene spheres and atmospheric pressure tank
• Chaired API Storage Tank Committee on MACT rule for Refineries, Distribution Facilities & Marine
• Did peer evaluation of EPA “TANKS” program, provided industry-wide data to calibrate calculations