Engineer Process

Gary B. Hansen

Perry, Utah

Email: *********@*****.***

Home: 435-***-**** Cell: 361-***-****

Process/Production Engineer

Skilled process engineer with supervisory experience and proven track record of innovation and process improvement. Broad

experience in chemical, utility, energetics, and plastics processes. Sound knowledge of solids handling, solid-liquid separation,

and crystallization systems. Robust engineering and software skills. Proven ability to successfully contribute to and implement

major projects. Good knowledge and experience with process safety management concepts such as Process Hazards Analysis

(PHA) and Management of Change (MOC). Key areas of expertise and skills are:

• • •

Process design/optimization Dust collection Six Sigma

• • •

Engineering supervision Dust explosion countermeasures HTRI modeling (IST)

• • •

Piping/pump design Milling /pulverization Minitab/JMP/Statistica

• • •

Crystallization Wastewater treatment design MS Excel, Word, PP

• • •

Centrifugation PSV/PRD sizing ASPEN/ChemCAD

• • •

Screening PSM/PSI/PHA/FTA/HAZOP/MOC AutoCAD

• • •

Safety shutdown systems Explosive synthesis/handling RAGAGEP

Professional Experience

ATK AEROSPACE SYSTEMS, Brigham City, Utah 2005- 2010

Producer of explosives, propellants, pyrotechnics, and aerospace systems

Process Development/Manufacturing Engineer

Developed process designs including to scale-up energetic materials (explosives) synthesis processes from Research and

Development (R&D) bench-scale to semi-commercial scale.

• Championed, marketed, and led successful initiative to recover significant quantities of high value product ($500-700/lb)

from waste materials. Proposed and led initiative to purify and reclaim waste solvent with potential benefit of

$100K/campaign

• Developed robust process designs including new comprehensive, scalable, customizable material balances, operating

instructions, etc. for scaling up first-time explosive manufacturing processes or processes inadequately documented and not

implemented in 5 to 6 years. Made significant process and safety improvements for each process. In each case, process

was safely and successfully implemented and customer expectations for quality and yield were met or exceeded.

• Developed, sponsored, and implemented key process and equipment upgrades including capital upgrades to replace

deficient, unreliable process chiller with new, reliable chiller for nitration processes and to install/upgrade tanks, piping,

and instrumentation to proactively reduce hazards in handling of Class IB flammable liquids and appropriately address

static electricity hazards per RAGAGEP.

Executed process improvements to significantly reduce volatile organic chemical (VOC) emissions from

crystallization process and minimize personnel exposure to toxic chemicals in nitration process. Made

improvements in process instrumentation and fall/slip protection.

Designed and installed emergency power systems for critical reaction operations.

• Drove improvements to programmable logic controller (PLC) and associated interlock systems at major scale-up facility.

Discovered and drove correction of PLC programming flaw causing failure of rupture discs. Checked out and verified

safety interlocks. Developed operating/control countermeasures for self-heating reaction. Constructed software templates

to log/archive critical process data from scale-up unit PLC.

GREAT LAKES CHEMICAL CO., El Dorado, Arkansas 2004-2005

Producer of brominated chemicals and flame retardants

Gary B. Hansen

Perry, Utah

Email: *********@*****.***

Home: 435-***-**** Cell: 361-***-****

Process Safety Management Engineer

Catalyzed improvements in process safety. Generated initiatives to upgrade MOC process and P&ID content.

Gary B. Hansen

Perry, Utah

Email: *********@*****.***

Home: 435-***-**** Cell: 361-***-****

CELANESE CORPORATION, Bishop, Texas 1988 - 2004

Producer of organic chemicals and engineering plastics

Contract Engineer (2004)

Verified sizing and adequacy of pressure relief devices per ASME/API.

Member Polyol Task Force – Staff Process Engineer (2002-2003)

Identified and acted on opportunities to improve flagging business line.

• Developed off-site toll blending process to reliably produce high margin specialty product that contributed $500-700K/year

in incremental revenue and reduced off-spec inventory.

• Generated engineering solutions as member of Six Sigma team that increased production of and improved product quality

of a valuable byproduct - Annual impact: $600K/year.

• Provided leadership and recommendations on team that reduced off-spec make by 63%.

Engineering Group Section Leader (2000-2002)

Provided oversight and direction for up to 11 engineers in chemicals and utilities areas. Coordinated key cost savings

projects/initiatives, provided input and resources for economic evaluations, managed process safety program, developed

budgets, participated in college recruiting.

Senior and Staff Process Engineer (1992-2000)

Generated ideas and associated designs for reducing costs, provided process safety support.

• Developed and designed breakthrough byproduct production process. Allowed isolation and purification of valuable

byproduct, increased primary product rates, decreased operability issues and emissions, and provided much more unit

flexibility. Annual benefit: $3 to $4M.

• Initiated idea to re-build deteriorating, isolated unit in more strategic location. Championed idea in series of presentations

to management. Participated in all stages of design and start-up. Annual benefit: $1 to $2M.

• Originated, marketed, and designed innovative product recovery process. Annual benefit is $500K to $1.5M. Cost of

project was less than $500K .

Member Project Team Engineering Plastics Production Facility (1988-1992); Fuji, Japan; Taipei/Kaohsiung, Taiwan

Developed bid packages for key equipment and utility facilities. Coordinated detailed engineering and design and construction

of waste and wastewater treatment facilities. Oversaw and coordinated the work of approximately 10 contractors of various

nationalities. Acted as consultant for successful start-up of wastewater treatment facilities.

Education

Louisiana State University, Baton Rouge, Louisiana and West Texas A & M, Canyon Texas

Accounting, management, finance classes toward MBA. Fully admitted to LSU MBA program.

Brigham Young University, Provo Utah

Bachelor of Science – Chemical Engineering (Passed Engineer-in-Training -EIT, Examination)

Other Skills, Credentials, Awards

• Fluent in speaking and reading of Japanese, fundamental knowledge of Mandarin Chinese and German.

• Past city council-appointed volunteer and sub-committee chair, Corpus Christi, TX Sister Cities committee.

• ATK: Honored with 2 major, monetary ATK Achievement Awards (A3+) for innovations, process and equipment

upgrades, and successful improvement initiatives

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