Engineer Chemical Engineering
Resume:
Stuart L. McDonald
Washington, In. 47501
cell 361-***-****
***************@***.***
Process / Production Engineer
PVC Production/Supervision/New Product and New Equipment Testing and Evaluation/Customer Interaction/PHA Reviews/New Plant Start-up Experience/Process Troubleshooting and Improvement
A seasoned engineering professional with experience in the manufacturing environments of Borden Chemicals and Plastics, Westlake PVC, BFGoodrich, and Formosa Plastics companies. Also, years of experience of Process Engineering working for engineering companies supporting client companies’ capital projects. A proven track record of success in process engineering, production, and production supervision.
Experienced in Batch reaction/polymerization
Production Engineering and management
Generated plant record production of well over 500 million pounds of PVC.
Reduced manufacturing anomalies 40% through reengineering of manufacturing procedures.
Achieved 95% waste recovery of PVC solids during manufacture of resin.
Averted loss of customer account by reengineering of manufacturing processes.
Plant Start-up experience.
PHA and HAZOP Studies
Procedure Writing
Familiar with Polymerization Process Equipment
Experienced in all phases of manufacturing to encompass engineering, prototype development, test, production, QC, materials management, cost controls, purchasing and vendor/contractor negotiations.
BS, Chemical Engineering, Rose-Hulman Institute of Technology, 1979
Professional Achievements
Generated plant record production of well over 500 million pounds of PVC. Developed procedures to minimize downtime and maximize on-stream time and productivity including adjusting batch initiator loads and carefully co-coordinating maintenance efforts to minimize equipment downtime.
Reduced manufacturing anomalies 40% through reengineering of manufacturing procedures. Began flushing of blend tanks between product changes eliminating Inherent Viscosity (IV) non-compliance.
Achieved 95% waste recovery of PVC solids during manufacture of resin. Installed new equipment capable of producing sufficient pressure and flow rate to eliminate excessive carry-over of PVC resin.
Reengineered manufacturing processes averting loss of customer account. Tightened controls over original and standard formulations reducing the failure rates of manufactured parts.
Eliminated quality control problems through establishment of real-time relationship with raw material supplier, DOW Chemical. Arranged for proactive supplier notification of changes in their manufacturing processes enabling the revision of formulations in anticipation of the quality shifts.
Career History
Process Engineer (Contract) Eastman Chemical through Ford, Bacon and Davis
Kingsport, Tn
January 2020 to August 2020
Provide Chemical Engineering support for Eastman capital projects. This includes Pipe-Flo modeling of customer’s utilities systems.
Process Engineer (Contract) Archer Daniels Midland
Decatur, Il.
November 2018 to June 2019
Provide process Engineering support for a pilot plant jointly operated by DuPont and ADM. The plant is producing from Sucrose a component of a copolymer to be used for the manufacture of bottles. My role was to provide engineering support for shift operations.
Process Engineer, Shamrock Technologies
Henderson, Ky.
Sept 2016 to Oct 2017
Shamrock is headquartered in Newark, New Jersey and provides milled, recycled PTFE powders and wax blends for use in coatings and inks. My duties included investigation of new equipment and instruments.
Process Engineer, Qualex
Mt. Vernon, In.
Oct 12 2015 to April 8 2016
Provide process Engineering Support to client companies for capitol projects. This includes relief device sizing and specifications, hydraulics studies, P&ID development, PFD development, and instrument and equipment sizing and specifications.
Due to a slowdown in demand for engineering services from Qualex’s two largest customers, a number of Qualex employees, including myself, were laid off.
Process Engineer, Moore and Associates, Incorporated (MAI)
Mt. Vernon, In.
June 2013 to Oct 7, 2015
Provide process engineering services for client companies in the chemicals and plastics industries. The Specific work includes, but is not limited to, relief device sizing, hydraulics studies of piping systems, material and energy balances, developing equipment specifications, P&ID development, and instrument specifications.
I left MAI because the demand for engineering services was waning, and went to Qualex because Qualex is a more established firm that had never had lay offs.
Process Engineer, PCI Skanska April 2012 to May 2013
Evansville, In.
Provide consulting engineering services for clients, largely in the metro Evansville, In. Area. The Specific work includes, but is not limited to, relief device sizing, material and energy balances, developing equipment specifications, P&ID development, and instrument specifications.
I was laid off due to lack of work, but was recalled within one week. By this time, I had already accepted a position with MAI.
Process Engineer, Formosa Plastics Corporation September 2010 to April 2012
Point Comfort, Tx
Specialty PVC Unit
Provide Engineering support for a new 180,000 tons per year specialty PVC manufacturing plant. This support includes, but is not limited to, participation in PHA reviews, DCS sequencing trials, procedure writing, evaluation of new processing methods, and production start-up support.
By April of 2012 the start-up was essentially complete. I was looking for new challenges, which I found with PCI Skanska.
Process Engineer, IDEA, Inc. March 2006 to January 2009
Provide consulting engineering services for clients. Primarily for clients in the Mt. Vernon, Indiana area. The largest client being Sabic –IP, formerly GE Plastics. Small capital projects (under $10 million) for Sabic include work in the polycarbonate process, Phenol plant, waste water treatment, specialty polymer plant, and others. The Specific work includes, but is not limited to, relief device sizing, material and energy balances, developing equipment specifications, P&ID development.
IDEAs largest customer for the Mt. Vernon office was Sabic IP (formerly GE Plastics). Due to a decrease in capital spending by Sabic, I was laid off by IDEA in 2006. The Mt. Vernon office of IDEA has subsequently closed.
Process Engineer, R&D Consulting January 10, 2005 to March 2006
Provide consulting engineering services for clients. Specific work includes, but is not limited to, relief valve calculations for the Monochem, Inc. utilities plant, pipeline sizing for Ineos’ refrigerant R22 railcar unloading system, material and various capital projects for Rubicon, a Division of Huntsman chemical that produces di-isocyanates for polyurethane production.
I left R&D in 2006 to accept a position with IDEA.
Explosives Handler US. Army March 2003 – Jan 2005
Worked for the United States Army as a civilian employee in materials handling.
Process Engineer/PVC Production Superintendent: Borden Chemicals and Plastics, 1993-2002
As Production Superintendent, organized and led daily operations of PVC manufacturing plant. This includes direct supervision of four shift supervisors and one day supervisor, and indirect supervision of 26 shift workers. As a Process Engineer, supported manufacturing units of three sites (these are the Illiopolis, Il., and Addis, La. PVC plants, and the Geismar, La. complex which included PVC and VCM units, as well as methanol, ammonia, formaldehyde and acetylene plants). This support included, but was not limited to, providing engineering troubleshooting and process design. Developed scopes of work for capital projects, and developed PFDs and P&IDs for these projects. These projects include, but are not limited to, hydroclones for the Addis plant waste water system, and the HCl emissions reduction project at the Geismar VCM-E plant. Experience as a team member for the Geismar site hazard analysis (“HAZOP”) program, and helped develop guidelines for implementation of OSHA 1910 Hazardous Chemicals program.
BCP was an operating limited partnership which went out of business in 2002.
Production Superintendent: Westlake PVC, 1991-1993
Responsible for daily operations of PVC manufacturing plant including quality control and productivity, environmental compliance, safety, and supervision of plant operations personnel.
I left Westlake to pursue an opportunity in a larger plant with Borden Chemicals and Plastics.
PVC Production Engineer: BFGoodrich Company, 1979-1991
Oversaw quality and productivity of PVC process spanning four plants and PVC production units. Worked with R&D and Marketing to develop/implement new products and processes. This includes the introduction of new products and equipment, as well as customer interaction. During my years spent with BFGoodrich, I worked with Emulsion Polymerization Processes, Suspension and suspension blending resins, and mass resin polymerization and processing.
I left BFGoodrich to take a superintendent position with Westlake PVC.
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