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Process Engineer

Location:
Charlotte, NC
Salary:
120000
Posted:
January 25, 2024

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Resume:

Solutions-focused, motivated engineer with a comprehensive background in team leadership, process improvement, and staff training. Extensive experience in petroleum refining and contract engineering. Calm demeanor in the face of difficulties; ability to complete projects on time and under budget while working in fast-paced environments. Highly versatile; quickly masters new roles, responsibilities, technologies, and environments. Reputation for integrity, dedication, and work ethic.

CORE COMPETENCIES

Project Lifecycle Management • Cross-Functional Team Leadership • Staff Training & Motivation

Process Engineering Management • Quality Control •Process Safety Management • Proactive Problem Solving

Refinery Technical Service • Process Improvement • Cost Control • Compliance • Relationship Building+

SUMMARY OF EXPERIENCE: A graduate of the University of Tulsa with a B.S. in Chemical Engineering, developed a career working with engineering contractors and refining operating companies. Extensive experience in refinery technical service and process design. Performed successfully as the Lead Process Engineer on several multi-million-dollar projects. Also, provided on-site support for debottlenecking project development and staff enhancement support.

Experienced with a wide range of refinery technologies including Crude/Vacuum distillation, FCC, Delayed Coking, HF Alkylation, Hydrotreating (naphtha, distillates and gas oils), Reforming, Isomerization, Sulfur recovery, gas plants and utilities. Unit operations and support experience includes hydraulics, heat exchange, distillation, pressure protection, fired heaters, root-cause analysis, HAZOP studies, and others.

PROFESSIONAL EXPERIENCE

Senior Process Engineer (Ramboll Engineering) 2022-2023

Process engineer on several industrial projects:

-FEL-1 development for a confidential client expanding polyurethane foam production by building a new green field blending facility

-Cooling water capacity expansion evaluation for aluminum plant

-Cooling water capacity expansion evaluation for Herbalife

Senior Process Engineer (Trucent Renewable Chemicals) 2021-2022

Process engineer on project building a plant processing oleo chemicals. Responsible for specifying, issuing RFQ’s and placing orders for various pieces of equipment including vessels and instruments. Developing P&ID’s for vacuum column distillation, short path distillation facilities and oil dehydrators.

Senior Process Engineer (QualEx Engineering) 2017-2019

Responsible for providing refining technology subject matter expertise to support Process Engineering staff and clients while serving as a process engineer on multi-discipline project teams. Ensuring accurate process data for several new installations and equipment replacement projects (fired heaters, tanks, pumps, hydraulics, PSV’s, heat exchangers, pressure vessels including material of construction).

Process engineer on several pipeline projects, both product and crude oil.

Crude oil pipeline/refinery interface capacity expansion for Robinson, IL refinery

Product pipeline expansion for CountryMark Product Pipeline via pumping station revisions

Process Engineering Supervisor (HollyFrontier) 2015-2017

Responsible for supervising 8 process engineers providing process design and technical service to the refinery units. Achieved timely completion of numerous turnaround project designs for inclusion in a near-total plant turnaround.

Responsible for review and approval of all MOC projects for Process Engineering including temporary facilities

Senior Process Engineer (Ambitech Engineering) 2010-2015

Extensive process engineering experience and ability to build relations was employed to enhance clients’ staff for Phillips66/ConocoPhillips.

For the Phillips 66 Lake Charles Refinery, prepared front-end engineering for estimating costs in developing long-range capital plans.

Analyzed options to develop plans for projects to meet EPA proposed Tier 3 gasoline requirements. Analysis of unit revamp options indicated that a new $15MM grassroots hydrotreater design was warranted

Provided front-end engineering for evaluating multi-faceted options for processing Canadian Dilbit crudes and US light, tight shale crudes by modifying several combinations of existing facilities

Developed HYSYS simulations of the Fuels Crude/Vacuum unit to evaluate processing a lighter crude slate of Arab Medium/Eagle Ford blends

Provided front-end engineering for a “Class A” Design for recovering diesel from a vacuum unit column. The addition of new product draw system allowed additional diesel product recovery worth $2MM/year at a cost of $1MM

Developed HYSYS simulations for a aromatics (BTX) recovery project economic evaluation

For the ConocoPhillips Wood River Refinery, coordinated Management of Change (MOC) activities for the new Vacuum Distillation Unit and Delayed Coking Unit (CORE Project). Utilized the e-MOC KMS database system to ensure management of change procedures were followed for the main project designs as well as individual design change notices. In addition, developed front-end engineering plans for coping with anticipated increase in crude oil solids from processing heavier Canadian synthetic crude oils.

Sr. Process Engineer (C&I Engineering) 2009-2010

Maintained full accountability for executing all aspects of process project engineering for petroleum refinery and chemical industry clients.

Developed, and implemented an innovative methodology for effectively calculating historical sulfur emissions from a client’s sulfur plant flare for environmental consent decree negotiations.

Sr. Process Engineer (Calumet Specialty Products) 2008-2009

Performed a diverse range of day-to-day process engineering activities, with an emphasis on evaluating and researching the cause of periodic Crude/Vacuum Unit upsets. Effectively analyzed internal processes to define inefficiencies and provide expert recommendations to boost productivity and performance.

Conducted troubleshooting and resolved crude tower top temperature problem. Reduced incidences of re-running off-spec lube stocks requiring reduced crude unit rates. Achieved an estimated $10,000/day savings per reduced upset episode.

Sr. Process Engineer (Murphy Oil USA) 2006-2008

Played a key role in executing support for FCC and Alkylation Complex. Compiled and produced detailed monthly reports on unit operation for management support.

Gathered and analyzed data for NOx emissions testing to determine FCC unit baseline, instrumental to supporting employer in defining future business plans, strategies and establishing a consent decree negotiation strategy.

Utilized extensive technical and engineering proficiencies to develop a multi-faceted plan on the FCC using Grace Davison’s SuRCA gasoline sulfur reducing catalyst additive. Collaborated with staff members to provide complex technical input involving the use of the additive as an alternative to a shutdown during an FCC feed hydrotreater catalyst replacement.

Led cross-functional team that developed plan for interim handling of spent sulfidic caustic that satisfied all stakeholders. The plant-wide continuous service system was modified due to HAZOP and safety considerations without plant interruption.

Sr. Process Project Engineer/Manager (URS Corporation) 1996-2006

Served as an Assistant Process Engineering Department Manager, with accountability for leading a multi-industry experienced cross-functional team of 40 process engineers.

Evaluated operational issues and utilized results to allocate resources to project teams. Trained, mentored, and supervised entry-level engineers, playing a key role in their development and performance. Performed complex research and analysis and utilized findings to prepare performance appraisals and proposals and meet clients’ project design needs.

Played an integral role as a Process Project Manager for project to increase the crude oil processing throughput capacity of Calumet Lubricants, Princeton, LA Refinery by 50%. Steered the process engineering team in the execution of the process design and installation of modifications. The $5MM project was completed on schedule.

Applied technical expertise in evaluating the environmental issues associated with the proposed sale of a petroleum refinery (environmental due diligence).

Played a key role as Process Engineer and Process/Project Manager for a cross-functional engineering team in design of a contaminated groundwater recovery and remediation system at the Marathon Catlettsburg Refinery. Designed facilities to recover and re-process hydrocarbon contaminated groundwater.

Sr. Process Engineer/Supervisor (BP Oil Company) 1987-1996

Supervised and led team of 10-12 process engineers providing technical support to the Hydroprocessing, Aromatics, HF Alkylation, Delayed Coking, Offsites/Blending and Wastewater Treating processes at the Alliance Refinery.

Served as a key Member of team charged with updating the refinery capital planning strategy for the 1995-2005 timeframe.

Acted as the refinery liaison for a major project to install a Diesel Hydrotreater, including PSA unit for hydrogen purification, 40 MBPSD Jet Merox treater, 75 LTPD Sulfur Recovery unit, Sour Water Stripper, and storage and blending revisions.

Increased capacity of Delayed Coking Unit by 30% by redesigning a rate limiting furnace convection section. Project cost of $1.5 MM worth $2.6 MM/year.

Launched a multi-faceted successful processing of refinery slops through the Delayed Coker rather than the crude unit worth $800,000/year in incremental crude runs.

Integrated an ASO Washer System and Rerun Tower revisions to eliminate ASO incineration and reduce acid losses. The $5MM Project reduced acid losses worth $2MM/year. The project was awarded the Louisiana Governor’s Award for Environmental Projects.

Facilitated the successful processing of treated HF Alkylation ASO in the Dealyed Coker with no corrosion issues.

Appointed as the Lead Process Investigator for Catalytic Reformer reactor damage. This damage, occurred during catalyst in-situ regeneration, caused by excessive temperatures from combustion of dense coke formed from maldistribution in the reactor during operation.

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Conducted troubleshooting and resolved problem with the production of non-aromatics in the Toluene Dealkylation Unit's Hydrotreating Reactor.

Promoted project for the addition of a refrigeration/chilling process for recovery of Benzene from Toluene Dealkylation Unit's off-gas stream (worth almost $2MM NPV with a 23% IRR).

Developed and implemented a resolution to a Sulfolane Aromatics Extraction Unit, rate-limiting relief condition by re-rating some equipment (potentially worth $1-2MM/year and eliminating a safety concern).

As an Alliance Refinery HF Alkylation expert, served on corporate task force to establish refining Department approach to HF Alkylation HF mitigation concerns.

Devised, justified and executed project to install a Pro-Quip Cryo-Plus liquid recovery unit to recover light olefin (propylene and butylenes) from fuel gas that included an $18MM project recovered 2000+ BPD for feed to the alkylation unit (or sales), worth. $10MM/year.

Revamped an existing Wastewater Treatment plant to meet the required specifications for Benzene NESHAPS.

Team member charged with the evaluation and design review to improve the adequacy of the flare system and improve the reliability of the flare tips and ignition system.

Process Engineer (Farmland Industries Inc.) 1985-1987

Performed general process engineering technical services and project process design at the Coffeyville, KS Refinery.

Participated in project to convert a reformer into a Total Isomerization Process (TIP) C5/C6 Isomerization Unit. Supervised loading of the TIP adsorber beds and provided start-up and operating support.

Distillate Hydrotreating: Produced a budget design for a grassroots facility for diesel hydrotreating in response to Low Sulfur Diesel regulations.

Staff Process Engineer (Conoco, Inc.) 1979-1985

Performed general process engineering technical services operations support and project process design.

Revised Delayed Coking furnace with a new stack, waste heat boiler and provisions for the addition of a fifth cell in parallel with the existing four cells.

Justified the conversion of an existing tower to stabilize coker gasoline and recover olefin at a cost of $1MM; a $500,000/year benefit.

Process lead in replacing condemned coke drums.

Initiated, justified and designed a project to insulate the drum overhead lines at a cost of $300,000 with a one-year simple payout.

Conducted the preliminary analysis to expand the coker from 20 MBPSD to 23.5 MBPSD.

Catalytic Reforming/Naphtha Hydrotreating: Operations Supervisor (relief) for an $8MM revamp of a reformer (including new radial-flow reactors, new feed/effluent exchange and furnace revisions) and the subsequent start-up and operation.

Evaluated and designed necessary revisions to improve the adequacy of to the East Plant flare system (crude/vacuum unit, FCC, naphtha hydrotreater and reformer).

Produced design to reduce inventory requirements. Project cost of $1MM saved $4MM over project life. Evaluated options and established path forward for reducing losses from a condemned vapor recovery balloon system.

Process Engineer (Conoco Inc.)1981-1982)

Performed general process engineering technical services. Plant closed 1982.

Process Engineer (Conoco Inc.) 1979-1981

Design team member that expanded the Lake Charles Refinery Premium Coker Unit to four drums and 1200 ST/SD. Project required extensive field checking, fractionator simulation, existing equipment, evaluation and the specification of new equipment including an additional furnace.

EDUCATION & AFFILIATIONS

University of Tulsa, Chemical Engineering

Prima-Tech Process Hazard Analysis HAZOP Leader Training

John Zink Burner School

SOFTWARE

HYSYS

Pro-II

Mathcad

Navisworks

Bluebeam

AFT/Fathom

Visio

Pipe-Flo Advantage



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