Patrick K. Moore, Sr. Process Engineer

Description

I have worked 28 years in the chemical/petroleum industry in process-development, process-control, process-improvement, and process-troubleshooting (20 years at Dow Chemical's Freeport site in Epoxy R&D and Hydrocarbons R&D; 7 years at Marathon Oil Company in Houston; 1 year as Process Engineering Manager at CHEMIC Engineers).  I have participated in several major alternative feedstock process development efforts, including methane-to-fuels process development and methane-to-olefins process development. Through these projects I gained experience with process-development and simulation/modeling of thermal gas-phase reactions, gas-phase (fixed-bed, moving-bed, and fluidized-bed) and liquid-gas (trickle bed) heterogeneous catalytic reactions, and liquid-phase reactions, both catalytic and non-catalytic.  I designed laboratory and pilot-plant equipment for these projects and worked closely with operating personnel in the interpretation of experimental data and the design of experimental studies.  The economic driving force for these projects was to reduce feedstock costs and eliminate or reduce undesirable waste-byproducts and waste-water. 

 

While at Dow Chemical, I participated in the process development of two major commercial implementations of new process technologies. I developed a fundamental reactive-distillation model which was utilized for design of a major commercial implementation (400 million lb/yr) of a new-process technology for a key specialty-chemical intermediate (epichlorohydrin).  For a major expansion of a liquid epoxy resin plant utilizing new technology, I integrated the new unit into the optimal-control algorithm of the existing plant.  

 

During my time at Marathon Oil Company I was extensively involved in the development of the GTF (gas-to-fuels) process, which utilizes the bromination of methane to form methyl-bromide which is then converted to hydrocarbons over a zeolite catalyst. Through interaction with the development team (including colleagues from Marathon, the contract laboratory, and the Engineering Contractor), I have been able to provide a better fundamental understanding of key process steps which in turn has led to significant cost reductions.  Some of these novel improvements have been submitted as invention disclosures (one application published).   

 

After the GTF project, I provided Process Engineering support to Marathon Oil’s oil and gas surface facilities (pipe-line from well-head to facility, gas-oil separation and liquid stabilization, gas-treating, and gas-compression), primarily in the safety area (flare and relief systems).  This was new and interesting work and provided a great “hands-on” experience with both small facilities in Texas and a large facility in Equatorial Guinea, West-Central Africa. 

 

During the past year I have been serving as the manager of the Process Engineering Group (3 to 5 engineers) for a small engineering consultancy firm, CHEMIC Engineers.  Most of the process engineering efforts during this time have been in support of a key client planning a 100 ktpa expansion of a specialty monomer plant involving new proprietary technology.  The client company had purchased this facility from another company, and while the local operating personnel at the plant possessed excellent technological experience and expertise with their process, they did not have access to the process engineering group from their original parent company.  My group at CHEMIC was able to provide them with the skills and expertise (process simulation, equipment design, vendor quotations, line and pump sizing, physical property modeling, separation design, including distillation, absorption, extraction, etc.) needed for the Conceptual and FEED engineering stages in support of 30% and 10% capital cost estimates for company project authorization and in preparation for the Detailed Engineering Design package.

 

Location
Houston, Willing to re-locate or travel to field for extended time.
Experience

20 years in Process Research (technology development) and plant support for Dow Chemical in Epoxy Products and Intermediates and in Hydrocarbon production.

7 years at Marathon Oil (upstream) in technology development and support of oil and gas surface facilities in Texas Eagle Ford shale and in Equatorial Guinea, West Africa.

2 years at CHEMIC engineers supervising process engineering group. In support of client's 100 ktpa expansion, provided them with the skills and expertise (process simulation, equipment design, vendor quotations, line and pump sizing, physical property modeling, separation design, including distillation, absorption, extraction, etc.) needed for the Conceptual and FEED engineering stages in support of 30% and 10% capital cost estimates for company project authorization and in preparation for the Detailed Engineering Design package.

Skills

Process Simulation (Steady-State and Dynamic; Aspen-Plus; Aspen Custom Modeler; Aspen-Dynamics; Aspen HYSYS)
Capital Cost estimation - Aspen Icarus software.
Economic Evaluation.
Process Technology Delevopment
Process Technology Selection
Thermodynamics
Physical Properties
Electrolytes
Corrosion
Materials of Construction
Flare and Relief design and troubleshooting
Equipment design
Heat and Mass transfer
Distillation
Gas-liquid-solid particle separation
pipeline hydraulic calculations
Process Control (control loop design and tuning; control loop equipment)
Production Plant troubleshooting during startup (utilizing process data from data historians; familiar with several process control/ data-logging systems, including Infoplus 21 and SCADA systems).

Education

Ph.D. Chemical Engineering, Texas A&M University, GPR: 4.0/4.0, Starting Date: August 1983.
Graduation Date: August 1988. Dissertation Topic: A Continuous-Lumped Phase-Equilibrium Model for Complex Multiphase Reactions. Advisor: Dr. R. G. Anthony

B.S. Chemical Engineering, Texas A&M University, Cum Laude.
Graduation Date: December 1980.

Contact Information