Engineer Project Manager

David W. Mauterer

Senior Process Development Chemical Engineer

Atlanta, GA and Milford, CT

Cell: 404-***-****

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

Summary: Over 20 Years of CO2 and Gas Separation Process Design; Alternative Fuels to Energy Process Development; Organic-Inorganic Specialty Chemical Processing; Industrial Gas Compression and Separations design for gases; O2-N2 and CO2.; Food and Juice Processing; FEL Gas process design, Fuel Reforming, and Commercial Fuel Cell systems. Overall Project Management

Education: Bachelor of Science in Chemical Engineering, University of South Carolina

Masters in Chemical Engineering Degree Courses Completed Western New England College, 2004

Process Simulation Software Experience in Aspen, ChemCad, Hysis, Pro II, Matlab

Fuel Cell Energy, Contract Process Engineer DOE NETL CO2 Recovery Project Engineer, Danbury, CT

Commercial Stationary MW Level Power Fuel Cells

Dec 2011 to Present; Phase I Contract

• Application of MW Molten Carbonate Fuel Cells to Coal Plt Exhaust CO2 Recovery: Process development of integration of large scale 550 MW fuel cell stacks into CO2 recovery via Refrigeration Condensation recovery. Project cost estimation; large scale process equipment evaluation and sub-contractor management. SynGas-CO2 distillation development and AARP chilling integration.

• Solid Oxide DOE Fuel Cell Demonstration and Design: Small Advanced Technology Team executing a ground up 60kW fuel cell with high electrical efficiency. Large pilotplant testing.

Gas Equipment Engineering Corporation and Avalence, LLC, Sr. Process Engineer, Milford, CT

Cryogenic and VSA N2 and O2 Generation and High Pressure Hydrogen Electrolytic Systems Development

April 2010 to Mar 2012 Currently Consulting to Avalence on Electrolyzers

• High Pressure Electrolyzer Hydrogen Generation System Development: Intense process development of high-pressure alkaline electrolyzers utilizing cylindrical electrode cells for generating high purity H2 and O2 product gases. Commercial product and process improvements and hydrogen generation scale-up of technology for DOE goals. Transition Metal catalyst applications, high flow recirc electrode designs; polymer ionic membrane testing; high pressure level controls evaluation. R&D system operations.

Hydrogen Industry fueling and cascade storage; composite storage systems for Bus and Fuel Cell vehicles. Hydrogen compressor integrations from 6000. to 10,000.psig; EN Iso standard process vessel designs; On-going development of large diameter carbon fiber wrapped electrolytic cells to 3000.psig for future DOE H2 supply infrastructure.

• Naval and Military N2 -O2 gas Separation Purification Systems: Engineering design of vapor swing adsorption (VSA); membrane and cryogenic air separation gas generation systems for Naval Aircraft carriers and military stationary systems.

• Cryogenics: Complete process simulations of cryogenic air separation plants and CO2 products. Applications of complex thermodynamic cycles utilizing refrigeration; diaphragm compression; JT valves; expanders and pulsating Q-drive liquefiers; HP and LP distillation techniques and liquid pumping.

PetroAlgae Inc., Contract Consulting Process Development Engineer, Sebastian, Florida

Micro- and Macro-Algae Harvesting of Biomass with Pyrolysis and Protein Extraction

March 2008 to March 2010; 2 year contract

• Development of CO2 Extraction Process from Flue Gas: Diesel generator exhaust CO2 recovery system supplying CO2 to aquaculture ponds. Low pressure coal plant flue gas scrubber and CO2 extraction designs to deliver economical CO2 gas mixtures to algae growth reactor ponds. Patented co-current scrubber devices with designer solvent and membrane concentration systems. Built and operated proof-of-concept systems. Developed Heat-Mtl balances; ChemCad process simulations of small and large scale algae drying systems with combustion controls; ground–up system planning and fabrication in aqua-culture environment.

• Development and Fabrication of Entire Protein Extraction System for Biomass: Designed and fabricated algae protein extraction system utilizing screening and milling for juice extraction. Built and tested many unit ops for: solids transfer, dewatering,HTST pasteurizers; screw press filtration techniques, centrifuge and modification of spin flash and spray dryers to yield high grade protein and biomass. Extensive separation techniques planned and developed for protein extraction yielding high-grade animal feed. Retrofit of a large spin-flash dryer for biomass. Fatty Acid and alcohol conversion Pilot-plant Lab operations for oil and hydrocarbon extractions.

Plug Power, SOFC Lead Process Development Engineer, Latham, NY

Global Commercial Supplier of Fuel Cell Units for Mobile and Stationary Backup Power

August 2006 to July 2008 22 month project Contract

• Development of Integrated High Temp Solid Oxide Fuel Cell (SOFC) Reformer: Process and mechanical responsibility for comprehensive design and development of reformer and integrated balance of plant (BOP) with joint venture cell stack firm. Extensive use of exotic alloys and plate-fin-catalytic cores. Extensive front end fuel reformimg calculation duties for alternative fuels and anti-coking techniques.

• Comprehensive Aspen Process Simulation Designs: Ultra high temperature gas processing with inconel brazed plate-fin heat exchangers (HEX) and catalytic fuel reforming unit operations. Multi-fuel, front-end reforming/processing designs. MUSE plate-fin designs and patented fuel humidification. Successful design and testing of catalytic converters and tail gas oxidizer reactors; CPOX, ATR and internal reforming reactor designs over broad operating regimes.

• Exotic Nickel Alloy Construction Applications for 1000 + Degrees C Fuel Cell Reformer: Part of small team which executed extensive mechanical designs and fabrication. Inconel plate-fin heat exchanger designs using patented fuel humidification integrated with heat recovery. Utilized proprietary PLATEFIN design software for heat exchanger design. Detailed welding, brazing and heat-treating of nickel and chromium alloys.

• LabView; Controls Integration and Pilotplant proving for Beta Generation SOFC System

• Three Patent Disclosures for Integrated Plate Fin HEX’s with Humidifier Wicking: Catalytic wash coat unit design/operation. Military fuel catalytic desulfurization applications for SOFC APUs. Extensive technical writing of DOE proposals for fuel cell power plants.

Fuel Cell Energy, Lead Process Development Engineer, Danbury, CT

Commercial Stationary MW Level Power Fuel Cells

July 2004 to August 2006

• Development of MW and Sub-MW Molten Carbonate Fuel Cells: Process development of molten carbonate fuel cells. Initiated and developed all process and instrumentation diagrams (PIDs). Developed complex ChemCad process simulation models for entire power plant including process air delivery, fuel/water ratio controls, process heat exchangers, gas flow distribution, control valve sizing and optimization, carbonate electrochemistry, cathode and anode recycle techniques.

• Hydrogen Highway Systems: CO2 separation from hydrogen exhaust stream with PSA mole sieves designed and integrated into commercial molten carbonate fuel cell systems. Air Products joint venture for California installation.

• Commercial Front End Fuel Pretreatment: Developed and patented hot fuel humidification heat exchanger integrated solutions, fuel desulfurization techniques and Gibbes reactor-monolithic catalytic core designs.

• Successful Mechanical / Process Installations: Direct-fired combustion systems integration. Critical high-temperature and phase change heat exchanger development applications, flow meter controls, safety relief valve sizing, OEM powerplant fabrication manufacturing. Equipment specification technical writing. Hazop and FEMA analysis of processes. Fuel-air ratio flow control; vessel designs per ASME and NFPA. Heatran Aspen heat exchanger simulations.

HydrogenSource, Senior BOP Engineer and Process Development, South Windsor, CT

Joint Venture of United Technologies Fuel Cells and Shell Oil; Manufacturer of Commercial Phosphoric Acid Fuel Cells; Hydrogen Reformers and Solid Oxide Fuel Cell Power Plants to NASA, DOD, and DOE

2001 to July 2004

• Balance of Plant Engineering: Process development of hydrogen synthesis reformers for commercial 150kW PEM Fuel Cell power plants utilizing Shell Catalytic Partial Oxidation Technology. Project lead in successful implementation of critical modifications. PID development, heat-mass balances, fuel-air ratio flow controls, thermal fluid management systems, specs for sensors, flow control valves, implementation of CAN-Field bus data communication systems, high accuracy primary flow sensors. Plate-fin heat exchangers, catalytic conversion beds related to CO elimination.

• Team Goals Met: cost reduction targets, energy parasitic power reduction and simplification of process. Long-term pilot plant testing and operations, and mechanical component lab testing with hands-on problem solving.

Contaminant Separations Inc., Process Engineer and Chief Project Manager, Atlanta, GA

CO2 Extraction and Recovery Systems Provider to the Alternative Energy Generation Industry

1992 to 2001 Multiple-Generic Patents for Physical Solvent Gas Absorption

• Project Management: Managed engineering and construction of gas separation units with emphasis on recovery of CO2 and removal of VOC emissions from combustion flue and waste gas sources. Process and mechanical design, ASME code vessel customization, fabrication shop management, cost estimates, purchasing, expediting, start-up duties, field modifications, testing data collection. Successfully managed +$10 million budgets for gas processing skids including shop construction. Performed all testing, and start-ups.

• Gas Turbine Applications: Fuel Treatment for stationary turbines and ICEs in 13MW generation systems. Air to fuel ratio system designs and emission controls for gas combustion turbines for LNG and CO2 recovery. . Selective emission conversion and condensing removal techniques meeting southern California air emission standards.

• Gas and Liquids Processing Development: Developed and patented gas treating and separation methods incorporating the successful application of brazed aluminum plate-fin heat exchanger assemblies as multi-component gas absorbers capable of maintaining isobaric condensing with predictable dew-point temperatures. Successful use of multiple plate-fin units into a modularized refrigerated assembly and the successful application as co-current and counter-current gas absorption towers. Successful development of bio-degradable and easily-regenerated isoprene solvent formulations for CO2 absorption far surpassing amine-MEA solvent regeneration requirements. Successful vacuum solvent flash and stripping tower development.

• Desulfurization, NOx, Organic Sulfur and VOC Organic Absorption Removal to ppb ranges utilizing unique regenerable isoprene-based solvent formulations for wide array of syngas streams: exhaust gas feedstocks, natural gas streams,and high CO2-content streams. Selective converters and gas flaring units meeting southern California air emission limits.

• R&D and Power Generation Site Operations: Five years of pilot plant operations at waste gas collection sites, evaluating coolant and plate-fin tower thermal and mass transfer performances. Regenerable Adsorbent evaluations for VOC-contaminant selective removal and process gas dehydration capacities. Thermal and pressure swing adsorber designs successfully built.

• LNG Applications: Back end system product methane purification; compression and liquefaction applications for Landfill gas; natural gas and waste gas streams. Application of pulsating Q-drive liquefiers; JT effect valves and multi-stage compression for product gases. Amine solvent experience at refinery and well gas sites.

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Amerada-Hess, Refinery Process Engineer, Gulf Coast Refinery

Domestic US Refinery; First position as Engineer

3 years of Refinery Experience

• Comprehensive Refinery Process Engineer Revamped distillation towers for thru-put, Aldehyde unit improvements. Compressor overhauls, Tracked Flexicoker data, TCC catalyst unit. Replaced control valves, Sulfur Removal operations; Extensive heat exchanger evaluations, Storage tank installations, Amine gas treating upgrades, overall plant natural gas collection systems management.

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