CAREER SUMMARY

Over twenty years of progressive experience including, but not limited to:

Process design & development

Process modeling & simulation

Chemical reaction engineering

Heat transfer

Combustion improvement & tuning

Air pollution control

Data analysis & statistics

Plant data extraction and analysis

Research & Development

DoE planning and execution

Energy industry

Environmental industry

EMPLOYMENT

CompRex/BGTL (La Crosse, WI) December 2014 – June 2021

Senior Design Engineer / General Manager

Process modeling / process development:

oXtL, other HC processes, sH2O purification, Brayton cycle sCO2 power generation.

oP&ID drawings; equipment sizing.

oProcess control logic development for modular systems control.

oIn-house test rig design for pilot testing and processes’ proof-of-concept.

Custom designed compact heat exchangers to client specification.

Designed compact heat exchange reactors to client specification or to fit within BGTL process.

Developed novel heat exchanger design.

Cowrote proposals resulting in over $3 million in grant money

Evaluated diffusion bonded blocks for ASME acceptance and advanced material consideration for heat exchangers, including metallurgical sample analysis and microscope evaluation.

Wrote technical reports for project results.

Designed experiments; developed and executed the testing protocols.

LP Amina (Charlotte, NC) April 2013 – December 2014

Research & Development Group Director of Research & Development, USA

Worked on multi-national research projects.

Developed process for new technologies from bench scale to pilot plant and first commercial project.

Modeled new technologies and worked with CFD modelers and Aspen flowsheet developers to optimize process.

Tested and optimized new commercial technology and trained new operators and engineers on operations.

Coordinated and led research projects of multiple research institutes and universities.

Chart Energy and Chemicals (La Crosse, WI) May 2011 – March 2013

Reactor Development Group Applications Chemical Engineer II

Developed specifications for a compact heat exchanging reactors.

Sized reactors and determined operating conditions for Fischer Tropsch reactors and systems.

Created marketing literature and presentations.

Wrote proposals for reactors.

Composed a potential client database for Fischer Tropsch plants.

Nalco, Inc. (Naperville, IL) May 2008 –January 2011

Nalco Mobotec Field Research Scientist

Performed data analysis and PI data extraction, organized and analyzed plant data.

Tested utility and industrial boilers, including tangential-fired, wall-fired, stoker boilers.

Oversaw performance test and documented results for multi-pollutant reduction controls, including NOx, SOx, and mercury.

Supported tuning of ROFA/Rotamix system installations for NOx reduction.

Oversaw tuning and performance test for co-firing biomass fuels with coal-fired boiler for reduction of nonrenewable CO2 emissions.

Evaluated fireside chemical treatment injection to reduce slagging and fouling in boilers.

Evaluated flow sensors for inline SOx sorbent.

Performed laboratory work for ashing characteristics of coal and biomass fuels.

Performed laboratory work to determine chemical additives and biomass blending to improve slagging and fouling characteristics for co-firing boilers.

RMT, Inc. (Madison, WI) September 2001 –May 2008

SmartBurn (previously of Alliant Energy) Combustion Research Engineer

Developed and supervised parametric testing based on statistical design of experiments at coal-fired power plants for boiler combustion optimization and emissions reduction.

Tested cyclone-fired, wall-fired and tangential-fired boilers, resulting in new operational procedures and control logic curve implementation for reduced emissions.

Performed statistically-based data analysis and PI data extraction and analysis for plant data.

Trained new employees on SmartBurn technology and equipment.

Designed and built flue gas extraction train system for backpass matrix sampling.

Led in researching, designing and implementing a number of projects such as an advanced OFA nozzle design and cyclone slag level indication.

Participated in OFA designs and control logic upgrades.

Developed RFP for neural network for combustion optimization and led the vendor selection process.

Participated in research for chemical injection (RRI and SNCR) for further NOx reduction as well as potential methods to help eliminate or reduce the size of an SCR.

Results:

oCyclone units operate as low as 0.17 lb/MMBtu NOx at full load: best-in-class without chemical injection.

oT-fired boiler as low as 0.13 lb/MMBtu NOx.

oW-fired boiler without an OFA was reduced from 0.30 to 0.22 lb/MMBtu NOx via operational changes only.

UOP, LLC (Des Plaines, Illinois). 1998 – 1999

Engineering Science Skills Center Reactor Modeling Internship.

Researched and modeled kinetic models for various processes. Determined process feasibility for reactor designs.

Programmed user interfaces for process models. Designed and implemented automated catalyst screening calculations. Incorporated unit operation models in HYSYS. Automated database storage and query searches of simulation results.

Processes included: HF Alkylation, Catalyst Regeneration, LAB Production, Onboard Fuel Generation, Stationary Fuel Generation, Dehydrogenation.

University of Houston (Houston, Texas) 1993 – 2001

Chemical Engineering Dept. Teaching Assistant/Research Assistant

Developed a unique procedure for varying the catalyst loading on ceramic foam.

Measured the Heat Transfer Coefficients of foam-supported catalyst. Developed a 2-D reactor model for foam and pellet catalysts.

Developed methods to incorporate reaction kinetics into advanced Monte Carlo techniques for polymer reaction and rheology studies.

Implemented nonisothermal rheology into kinetic theory models. Employed numerical methods using Finite Element, Finite Difference, and CONNFFESSIT. Simulated the effect of temperature and temperature-dependent variables in dilute polymer solutions.

Studied: Reaction Engineering, Catalysis, Catalyst Preparation, Effective Transport Properties for Heterogeneous Systems, Polymer Rheology.

EDUCATION

Ph.D. in Chemical Engineering 2006

University of Houston

Measured the heat transfer properties of reticulated ceramic foams.

Built an apparatus for measuring the heat transfer properties of the foam.

Developed a unique procedure for varying the catalyst loading on ceramic foam.

Optimized catalyst loading on ceramic foam supported catalyst for shell-and-tube reactors.

Developed a generic 2-D reactor model for foam and pellet catalysts to calculate heat transfers and varying reaction rates.

Reactors modeled include: o-xylene, ethylene oxide, methanation and steam reforming.

Teaching Assistant: Statistical Analysis, Stochastics, Transport Phenomena, Thermodynamics, Introduction to Chemical Engineering.

B.S. in Chemical Engineering 1993

Texas A&M University

Graduated Magna Cum Laude.

PATENTS

US2020/0294521A1 (Pub Date: 9/10/2020). Hani Ahmed Gadalla, Zhijun Jia, Thomas Parlow. “Compact heat exchanger with alternating fluid channels.”

US2015/032252, WO2015/179806A1 (Pub Date: 12/15/2016). Jens Assmann, Rainer Bellinghausen, Hani Gadalla, William Latta, Leslaw Mleczko, Matthew Targett, William Williams. “System and process for the manufacture of hydrocarbons and upgraded coal by catalytic mild temperature pyrolysis of coal.”

US9481577B2 (Pub Date: 11/1/2016). Matthew Targett, Hani Gadalla. “Reactor with induction heater.”

PUBLICATIONS & PRESENTATIONS

Zhijun Jia, Steven Vallee, and Hani Gadalla. “Compact Heat Exchange Reactors for Gas to Liquid Applications.” Natural Gas Conversion Symposium 10, Doha, Qatar (2, 2013).

Hani Gadalla, Zhijun Jia, Steven J. Vallee, Burton H. Davis and Dennis Sparks. “Comparing the Performance of Compact Heat Exchange Reactor to CSTR for Fischer-Tropsch Synthesis.” AIChE (Spring Meeting 2012).

Steven J. Vallee, Zhijun Jia and Hani Gadalla. “Fischer-Tropsch Synthesis Using a Pilot Scale Fixed Bed Compact Heat Exchange Reactor.” AIChE (Spring Meeting 2012).

Hani Gadalla, Zhijun Jia and Steven J. Vallee. “Economical Comparison of Compact Heat Exchange Reactors for a Small Fischer Tropsch Synthesis Plant.” AIChE (Spring Meeting 2012).

Steven J. Vallee, Zhijun Jia and Hani Gadalla “Fischer-Tropsch Synthesis Using a Pilot Scale Fixed Bed Compact Heat Exchange Reactor.” AIChE (Annual Meeting, 2012).

Zhijun Jia, Steven J. Vallee and Hani Gadalla. “Compact Heat Exchange Reactors for Process Intensification.” AIChE (Annual Meeting, 2011).

Zhijun Jia, Hani Gadalla, Steven J. Vallee, Burton H. Davis and Dennis Sparks. “Pilot Test for Fischer-Tropsch Synthesis Using a Fixed Bed Compact Heat Exchange Reactor.” AIChE (Annual Meeting 2011).

Baiyun Gong, Guisu Liu, Brian Higgins, Gary Cyr, Nathan Hyrne, Hani Gadalla and Tom Williamson, “CFD-based design and installation of cost-effective ROFA/Rotamix system for NOx reduction at RPU Silver Lake Unit 4,” Clearwater Clean Coal Conference: Clearwater Florida (6/2010).

Brian Higgins, Li Yan, Hani Gadalla, John Meier, Tore Fareid, Guisu Liu, Miroslaw Milewicz, Arkadiusz Repczynski, Michael Ryding, and Wlodzimierz Blasiak, “Biomass Co-firing Retrofit with ROFA for NOx Reduction,” Polish Journal of Environmental Studies. Vol 19, No 6 (2010), 1185-1197.

Brian Higgins and Hani Gadalla “Wroclaw retrofit demonstrates benefits of the ROFA system,” Modern Power Systems, Vol 30, No 4, (4/2010), p33.

Hani Gadalla, “Enabling NOx reduction with unburned carbon improvement and biomass co-firing through the installation of ROFA,” EXPPERTS Conference: Berlin (10/2009).

Brian Higgins, Li Yan, Hani Gadalla, John Meier, Tore Fareid, Guisu Liu, Miroslaw Milewicz, Arkadiusz Repczynski, Michael Ryding, and Wlodzimierz Blasiak, “Biomass Co-firing Retrofit with ROFA for NOx Reduction at EdF-Wroclaw Kogeneracja,” Energy Efficiency and Air Pollutant Control Conference: Wroclaw, Poland (2009).

Hani Gadalla, Nicholas Peters, Felicia Iman and Zhanhua Ma, “SmartBurn Approach for Reduced NOx Emissions Below 0.20 lb/MMBtu at Cyclone-fired boilers through Operational Testing,” Coal-Gen Conference: Milwaukee (8/2007).

Hani Gadalla, Frank Fowler, George Lala and Andy Redmond, “Implementing NOx Control at a Bleached Kraft Mill,” NCASI Conference: (5/2006).

Hani Gadalla, “Graduated loading of catalyst on reticulated ceramic foam,” Thesis Dissertation: University of Houston (12/2006).

Frank Fowler, Hani Gadalla, George Lala and Andy Redmond, “NOx Reduction in Coal-Fired Boilers Using Existing Equipment,” Engineering, Pulping, Environmental Conference – TAPPI; Philadelphia, (8/2005).

Vásquez E.R., Ma Z., Iman, F., Gadalla, H., “Smartburn® Technology Reduces NOx Emissions to 0.2 lb/MMBtu levels at Coal-Fired Edgewater Unit 4 Cyclone Boiler,” ELECTRIC POWER Conference; Chicago, April 5-7, 2005

Vásquez E.R., Avancha R., Gadalla H., Iman F., Lu P., McQuistan K., and Sears R., “Smartburn® Technology, a Cost-Effective Alternative for NOx Compliance in Coal Wall-Fired Boilers,” Proceedings of the 2004 ELECTRIC POWER Conference; Baltimore, Maryland, March 30-April 1, 2004.

Vásquez E.R., Mara F., Maas D.J., Ma Z., McQuistan K., Gadalla H. and Iman F., “Application of SmartBurn® Technology for NOx Control in Tangentially Coal-Fired Boilers,” PowerGen International; Las Vegas, Nevada, December 9 -11, 2003.

E. Vásquez, H. Gadalla, K. McQuistan, F. Iman and R. Sears, “NOx Control in Coal Fired Cyclone Boilers by Using Smartburn Combustion Technology,” Combined Power Plant Air Pollution Control Mega Symposium; Washington, DC, May 19-22, 2003.

H.A. Gadalla, C.C. Hua, and J.D. Schieber, “Nonisothermal Simulation of Polymeric Liquids using the CONNFESSIT Approach,” Proc. XXIIth Int. Congr. On Rheol., 399-400, Edited by A.Kadi, J.M. Dealy, D.F. James and M.C. Williams (1996).

Schieber JD and Gadalla H. “Nonisothermal simulation of polymeric liquids using the CONNFFESSIT approach,” 53rd Ann. Tech. Conf. (Boston, 1995)

H. Gadalla, K. Mahdi, C. Hua and J. Schieber, “Nonisothermal Flow in Complex Geometries using the CONNFESSIT Approach,” Meeting of N. Am Soc of Rheol., Sacramento, Calif. (9 Oct, 1995).

J. Schieber and H. Gadalla, “Energy Dissipation in Polymer Liquids,” AIChE Annual Meeting, California (16 Nov. 1994).

INSTRUMENTS AND EQUIPMENT

Portable Furnace Video Camera (Lennox FireSight Air Cooled Systems)

Ashing Furnace (AAF Model Carbolite Furnace)

Ash Fusion Temperature Apparatus (AF700 Model)

Thermogravimetric Analyzer (TA Instrument Q500)

COMPUTER SKILLS

FORTRAN (including creation of dll’s for integration with other software)

Visual Basic Application (VBA), including advanced programming within software like MS Excel

Aspen HYSYS, Aspen Plate-Fin Exchanger, Aspen Engineering & Design

Athena Visual Studio

MS Excel, MS Word, MS PowerPoint, MS Project

PROFESSIONAL ORGANIZATIONS & HONORS

Cyclone’s Users Group – 2005 to 2006

AIChE – member since 1991

TRAINING and CERTIFICATES

ASME BPVC Section VIII Div 1 certification – OneCIS 2021: Design and fabrication of pressure vessels

ASME BPVC Section IX certification – OneCIS 2021: Welding, brazing and fusion fabrication

Group Leadership Certificate Series – MRA 2008: Leadership and management training, problem resolution and communication skills

Root Cause Analysis – APOLLO 2007: Training on root cause analysis for problem prevention, equipment failure discovery and best practices identification

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