Engineer Process

KEN JOHNSON

**** ****** ******* ** **** Chester, Ohio 45069 513-***-****

************@***.***

Process ENGINEER

Senior Process Engineer specializing in scale-up of batch chemical process from laboratory to

commercialization. Possesses considerable experience in scale-up of supported catalysts for a

major polyethylene manufacturer with success commercializing catalyst systems for commercial

processes, design of pilot scale facilities, and operations supervision. Led and participated in

cross-functional teams for product commercialization. Demonstrated ability to commercialize

without pilot scale evaluations, significantly reducing development time and cost.

• Scale-up and commercialization of silica supported polyolefin catalysts for Slurry and

Gas Phase processes for polyethylene and polypropylene

• Skilled in pilot to commercial scale catalyst manufacturing technology

• Expertise in batch processing technology and hazardous/air sensitive chemistry

• Leadership/member of cross-functional teams / Stage-Gate Process

• Supervision of laboratory evaluations (bench scale polymerizations and polymer

characterization) and pilot operations and personnel

• Design and management for capital projects

• Good communication, documentation, and reporting skills with colleagues and clients

• Recognized as an effective strategic planner, troubleshooter, and problem solver (Stage

Gate Project Management, Kepner-Traego analysis)

• Managed regulatory compliance for catalyst scale-up operations (EPA-TSCA, OSHA-

PSM, DOT)

• Completed cGMP training

PROFESSIONAL EXPERIENCE

Specific Accomplishments

• Achieved successful commercial scale operation and earned enterprise –wide

achievement award for scale-up of Single-Site catalyst systems (3) for HDPE, LLDPE

and Plastomer products. Received 3-gram laboratory formulations and scaled 1,000x and

10,000x in pilot scale equipment. Overcame performance issues with key process

changes.

• Developed multiple catalyst systems for LLDPE gas phase processes, achieving

commercialization of two catalysts for high-performance LLDPE products. Developed

catalyst manufacturing specifications using DOE methodology. Prepared technology

transfer documentation and led catalyst commercialization through commercial catalyst

vendors.

• Commercialized value-added in-reactor TPO products for polypropylene process,

requiring design and construction of process equipment for Ziegler-Natta catalyst

manufacture. Demonstrated ability to scale subsequent formulations directly without

pilot scale evaluations, reducing cost and time to market.

• Ziegler-Natta catalyst scale-up resulting in development and commercialization of new

HDPE products. Generated additional revenue through licensing catalyst technology.

• Awarded 6 US patents and 4 pending in polyolefin catalysis.

• Authored Process Scale-Up Protocol for Stage-Gate Project Management.

• No safety incidents or OSHA recordables in more than 10 years for myself or direct

reports.

Novolen 4/2006-Present

Contract engineering (through CDI Corp) for laboratory scale Ziegler-Natta catalyst development

for polypropylene

Procter & Gamble 2/2005-12/2005

Contract engineering (through Adecco Technical) in Solids Processing at Central Engineering

Testing Laboratories.

Equistar Chemicals 1975-2004

Equistar Technology Center, Cincinnati, Ohio 1998-2004

Senior Research Specialist (Engineer III)

Directed scale-up of Single Site Catalyst program for Equistar.

Developed Unit Manual for OSHA Process Safety Management compliance and audit.

Completed design and supervised construction of pilot scale catalyst preparation facility.

Successfully completed EPA audit for developmental catalysts.

Responsible for managing capital spending projects.

Process Research Center, Morris, Illinois 1986-1998

Senior Research Engineer

Developed designs for pilot scale (commercial type process equipment) catalyst manufacturing

processes for polyethylene and polypropylene, and supervised construction of units.

Technical, supervisory, and training responsibility for operations and laboratory functions.

Coordinated regulatory compliance for catalyst areas (TSCA, OSHA, DOT)

Developed model for catalyst scale-up facility.

Research and Development, Rolling Meadows, Illinois 1974-1986

Research Engineer

Initiated scale-up of silica supported Ziegler-Natta catalyst technology resulting in pilot scale

evaluation of two systems and selection of one for commercialization.

Co-developed technology transfer documentation for licensing of catalyst technology.

Optimized catalysts for pilot scale evaluation for LLDPR process.

FORMAL EDUCATION

Bachelor of Science, Chemical Engineering

Illinois Institute of Technology, Chicago Illinois

(Graduated with High Honors)

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