SYNTROLEUM PILOT PLANT
The only US facility in 2004 that was able to produce diesel from natural gas, included reforming, Fischer Tropsch and product upgrade.
Became the Plant Manager under difficult circumstances. Syntroleum had tried to start this facility for 6 months with no avail. Financial partners were pressing for results. I lead the leadership team (Syntroleum-Marathon-Foster Wheeler) and solve all technological problems. Ultimately producing the 250 k gallons of fuel needed to fulfill Syntroleum contractual commitments.
AIR PRODUCTS AND CHEMICALS
I was the plant manager that design, troubleshoot and operated the ITM 24 KSCFD Syngas Pilot Plant. Major challenges due to high temperature and pressure. Testing new reforming technology using complex materials using syngas in the middle of Air Products headquarters in Allentown.
I started as Assistant Process Engineer and finish as Senior Process Engineer in the Process Development department. Developed the Fischer Tropsch slurry technology focusing in the solid-liquid separation process, patenting the results. Quantified the heat transfer, mass transfer and hydrodynamics in the reactor place them into a computer model that was used in the scaleup of the technology. The pilot plant was rated at 80 bpd and the commercial (this photo) was 2500 bpd.
I became responsible for operations while GPE was renting the GTI facilities in Chicago. The results made possible for the company to raise $ 130 MM.
Became responsible for the hiring and training of personnel in the pilot plant. I was responsible for the operation of the facility in Massachussets. The technology was demonstrated in September 2009. Many issues were solved related to coal feed, density control, fines control and temperature management.
BIOFUELS OF TENNESEE
Responsible for the troubleshooting and the redesign of a bio-diesel plant located in a rural area. The challenges were low budget, no man power and no infrustructure. The feed varied as the used cooking oil vary. The solution was to build a bench scale pilot plant to test each feed. Once characterized, the feed was run at the commercial plant. The product met ASTM standards allowing to be sold in the market place. This success led to the next level of investment. I participated in the design of the new plant that was built in Georgia.