Richard J. Kolodziej, M.B.A., P.E.
Process Technology Manager
Mr. Kolodziej has over 25 years of production and process engineering experience in the oil, petrochemical, and fine chemical industries. Areas of process engineering expertise include heat and material balances, PFDs, P&IDs, process simulation, economic evaluations, technology evaluation/development, process due diligence, hazard analyses, and detailed equipment design specifications.
Fields of experience include design and operation of the following refinery processes: crude pipestills, fluid catalytic cracking units, hydrocrackers, cokers, naphtha hydrotreaters and catalytic reformers, oxygenates production and conversion, isomerization units, distillate and gas oil hydrotreaters, sulfur plants, and alkylation processes. Other fields of experience include some aspects of: lube oil re-refining, air separation units, azeotropic distillation, mole sieve unit design, C5-C9 olefin and diolefin recovery and specialty processing, LNG and gas processing, alcohol production/purification, ethylene plant design, propane/propylene splitter design, oxygenates production, and ethylene oxide/glycol design and production, and ethanol production.
9/04 – today Mustang Engineers & Constructors, L.P. Houston, TX.
Responsibilities included all phases of process engineering management and technology evaluation / development, mainly in the Refining, Aromatics, and Petrochemicals industries. Helped seek out, develop, and then execute various front-end Process studies, including scoping studies and technology evaluations. Supervised process engineers while also developing technology positions, and assisting Sales in business development presentations and proposals. Project assignments included:
Process Lead for Gas Oil Hydrotreater and SRU Expansion Process Study. This work included several newer process and technology options to accomplish and justify the unit expansion. Various expansion rates and their affects were evaluated.
Process/Project Lead for a Sulfur Processing expansion study. This included suggesting Process options and then soliciting and evaluating technology options and risks. A variation of a newer developed technology was eventually recommended and chosen by the client.
Process/Project Lead for an Alkylation Unit study. This included soliciting and evaluating some newer technology options and risks. Reusing some idled equipment was included in the evaluation study.
Process/Project Lead for an MTBE Plant Expansion study. Process Technology enhancements concepts were included in the study design.
Process/Business Director responsible for the commercial development of an newer Oxidative Desulfurization Process for terminal applications. This work included co-developing/improving the Process Technology with Lyondell, including evaluating pilot plant data and then upscaling to a process design and reducing the capital and operating costs to make it commercially viable. This assignment also included evaluating the market potential and plan for this technology.
Process/Business Director responsible for some C4 through C9 Olefins/Dioelfins Recovery and various Specialty Chemicals processes and technologies. This work included co-developing/enhancing associated Lyondell technologies and processes to be used for client situations. This assignment included seeking and out suggesting Process options for potential Refining and Petrochemical clientele. This assignment also developed a technology partnership with Lyondell Licensing for some associated process technologies, including proposing and marketing to prospective licensors.
9/02 –9/04 CB&I Howe-Baker (formerly Petrofac) Houston, TX.
Responsibilities included all phases of process engineering management and technology evaluation / development, mainly in the Refining, Aromatics, and Petrochemicals industries. Supervised process teams up to 25, while also developing technology positions, and assisting Sales in business development presentations and proposals. Project assignments included:
Process Director responsible for the helping develop a Delayed Coking business. CB&I has been well-known for repairing old / building new coke drums and Coker unit revamp construction. This knowledge base, along with the addition of newer and safer deheading device technology upon the market, has allowed CB&I to expand its role into Coker Unit debottlenecking/expansion projects. This assignment also included evaluating the market potential and plan for the Delayed Coking business.
Process Director responsible for technical support of the S-Brane technology of FCC Gasoline Desulfurization. This work included improving the technology to reduce CAPEX/OPEX associated with a commercial design. This assignment also included evaluating the market potential and plan for the best uses for the S-Brane technology.
Process Director responsible for technical support for the preparation of the of the lump-sum bid for the Sempra Energy LNG Regassification facility off the west coast Baja Pennisula.
Process Director responsible for the commercial development of the Unipure Oxidative Desulfurization Process. This work included co-developing the technology with Unipure from pilot plant data and then upscaling the process design and reducing the capital and operating costs to make it commercially viable. This assignment also included evaluating the market potential and plan for this technology.
Process Director responsible for the Gas Oil Hydrotreater, ARU, SWS, and SRU/TGTU unit designs for a major refinery expansion for United Refining. This work included evaluating current unit capabilities to ensure required revamp requirements, as well as, new unit design definition. The project goal was to maximize the use of a modular design approach.
8/97 – 9/02 Aker Kvaerner (formerly John Brown), Houston, TX.
Responsibilities included all phases of process engineering management and technology evaluation / development, mainly in the Refining, Aromatics, and Petrochemicals industries. Supervised process teams up to 15, while also developing technology positions, and assisting Sales in business development presentations and proposals. Project engineering duties were included at times. Project assignments included:
Process Director responsible for coordinating the Clean Fuels initiatives for Kvaerner on a worldwide basis. This assignment included to evaluating the market potential in Clean Fuels related topics and developing focused marketing plans to pursue these initiatives.
Process Director assisting on the process development of the Distrigas LNG Regassification facility off the East Coast. This process design assignment included a novel way of reducing NOx production.
Process Director for the conversion of MTBE to Iso-Octane production. This work included co-developing the technology with Lyondell Chemical from pilot plant data and then upscaling the design for several Lyondell sites. These sites are now being detailed engineering. This assignment has also included developing a licensing partnership with Lyondell for this technology and helping them develop technology proposals and marketing for prospective licensors.
Process Director for the $160MM SINCOR Sulfur Complex in Jose, Venezuela. The scope included all the detailed process engineering for: two Amine Regeneration Units, two Sour Water Stripping Units, three Claus Sulfur Recovery Units; a Resulf Tail Gas Treating Unit; and Utilities and Offsites for the Sulfur Complex. The scope also included a performance test and guarantee for the non-licensed processes.
Process Technology Director for the Direct Olefins Hydration technology to synthetic alcohols. This work included evaluating and improving the technology design with Lyondell Chemical from pilot plant and operating data and then offering the improvements to potential clients. This assignment has also included developing a licensing partnership with Lyondell for this technology and providing technology proposals and presentations for prospective licensors.
Front-end engineering package for a barge-mounted, 36,000 barrel-per-day refinery for transport and installation in Papua, New Guinea. The scope included re-using/modifying some used equipment. New and used equipment design was optimized for various case scenarios.
Process consultant/project management assistance for a new refinery for the Republic of Georgia. This work included overseeing and coordinating among several subcontractors evaluating the design, marketing, and economic forecasts as well as environmental/site selection aspects.
Propane-Propylene Splitter expansion for Diamond Shamrock in Texas. The work included modeling actual plant performance data to evaluate existing equipment for future capacity increases. The new, unique design provided 30% more capacity for the same energy usage as traditional designs.
Process consultant for ethanol plant designs from sugar cane fermentation for multiple sites in Australia.
7/94 – 8/97 Valdes Engineering Company, Elmhurst, IL.
Responsibilities included: business development for all engineering and design work scopes, project and proposal development, as well as, all phases of process engineering management. Supervised six direct staff, while also being seconded for some process consultancy work. I was a Principal in the company, including signing authority as an Officer. Project engineering duties were required at times. Sales grew from $1.0MM to about $5.0MM during my tenure. The company staff grew from 11 to over 60 during that time. In addition to all business development activities, project assignments included:
Aromatics Complex for P.T. Trans-Pacific Petrochemical Indotama in Indonesia. Supervised preparation of UOP Basic Engineering Packages for an Aromatics Complex. The complex included the following units: pyrolysis gasoline HDT, NHT Unit, CCR Platforming, Sulfolane, BTX Separation, Isomar, Parex, and Tatoray.
Lube oil refinery due diligence and plant improvements for Enviropur in Illinois. The work included evaluating plant performance and suggesting, justifying, and then detail engineering plant improvements.
Gasoline Additives Plant expansion project for Exxon Chemicals. This project required designed tank modifications, new pumps, piping, and loading rack, railroad spur, and waste oil modifications.
Grass roots Lube oil re-refinery for Custom Blended Oils, Inc. of Peotone, Illinois. The work included the front-end and detailed engineering design for a grass roots lube oil re-refinery.
— Moreco Energy, McCook, Illinois. Capacity and operation upgrade study for lube oil re-refining operation.
5/93 – 7/94 Bechtel Corporation, Naperville, IL.
Responsibilities included all phases of process engineering management and design. PFDs, P&IDs, process simulation, and equipment sizing specifications. Project engineering also included in duties. Project assignments included:
Farmland Industries Coffeyville Refinery FCCU Expansion to riser cracking. Process simulation and design.
Clark Oil, Blue Island, Illinois, Isocracker HAZOP and Feed Heater Rebuild / Modifications Project. Process simulation, detailed design, and unit hazard review.
— Murphy Oil, Superior, Wisconsin Various refinery debottlneck/expansion studies using the PIMS LP model.
— UOP, Des Plaines, Illinois, UOP Secondment. Supervision of five process engineers seconded to UOP.
— UOP, Des Plaines, Illinois, UOP Process Support. Project management, process technical support, and overall supervision for the process design and CAD support for a Hydrocracking Unit design.
9/88 – 5/93 John Brown, Chicago Office, Chicago, IL
Responsibilities included all phases of process engineering management and design. PFDs, P&IDs, process simulation, and equipment sizing specifications. Project assignments included:
— Ryazan Refinery in Russia FCCU Expansion to riser cracking using Amoco Oil technology. Process simulation and design.
— Shymkent Refinery in Kazakhstan FCCU Expansion/Upgrade with UOP Technology. Process simulation and design.
— NREL, Colorado. Process simulation and consultation on ethanol recovery and dehydration sections for a waste to ethanol plant.
— Amoco Oil, Alaska. Process simulation and design for Hydrocracking section design of Gas-to-Liquids Demonstration Unit.
— Ecochem, Wisconsin. Process simulation and design for lactic acid production plant and azeotropic recovery systems.
— Refineria de Petroleo, Concon, Chile. Process design and Schedule A development for new UOP naphtha hydrotreater and CCR reformer.
— Amoco Oil Hydrotreating Technology Development. Process simulation and design. This technology was developed for distillate or gas oil hydrotreating, as well as, distillate hydrocracking scenarios.
— UOP, Des Plaines, Illinois/Thai Oil, Thailand. Detailed engineering for modular UOP Penex/Molex Unit.
— Missalco, Louisiana. Process simulation and design for ethanol recovery and dehydration section expansion for ethanol plant expansion.
— Amoco Oil Yorktown Refinery. Process simulation and design for revamp of a distillate hydrotreater.
— New Energy, Indiana. Process simulation and design for corn fermentation and ethanol plant.
— Crossfield Catalyst, Joliet, IL. Detailed process design for the expansion of a catalyst production line.
— Amoco Oil Salt Lake City Refinery. Process design for new distillate desulfurization unit (DDU).
— Amoco Oil Whiting Refinery. Process design work for DDU offsite project which included amine unit, sulfur plant, and tankage debottlenecking modifications.
— Nutrasweet, Augusta, Georgia. Process simulation and design for acetic acid recovery system.
— Akzo Nobel, McCook, IL. Process improvements audit and HAZOP of a hydrotreating catalyst facility. This effort resulted in the implementation of process energy and safety improvements.
5/85 – 9/88 Quantum Chemical Company, Morris, IL
Responsibilities included all phases of process design support. Duties also included troubleshooting and improving air separation, ethylene and ethylene oxide/ethylene glycol (EO/EG) plant operations. Major assignments included:
— A key member of Ethylene plant rebuild project.
— A complete process hazard review study of the ethylene plant.
— Implementation of a statistical process control (SPC) program for the: EO/EG plant, ethylene/propylene storage, and Utilities facilities.
— An Air separation plant modifications project.
— An Ethylene glycol unit expansion including a multi-effect evaporator section expansion, including technology evaluations.
2/83 – 5/85 Amoco Oil Company, Central Engineering
Responsibilities included process design work mostly for the Amoco Oil Texas City Refinery. Major project experience included:
— A FCCU expansion project to riser cracking. The project included a debottleneck of the Main Fractionator and Gas Con sections.
— An Aromatics recovery unit (ARU) improvements project.
— An Amoco Oil Whiting Refinery jet loss reduction program.
— An Ultracracker debottlenecking and improvements project.
— Coker Heater modifications project.
— A 25% crude pipestill expansion and energy improvements project.
— A new C5/C6 isomerization project.
6/81 – 2/83 Amoco Oil Company, Whiting Refinery
Responsibilities included troubleshooting unit upsets, measuring and improving performance of existing units, assisting in unit turnarounds, and developing small-scale process designs for plant improvements. Major project experience included:
— Process furnace efficiency improvement program.
— A corrosion reduction study for the lube oil plant.
— Crude preheat train fouling reduction program.
— Coker debottlenecking study.
— ARU simulation and energy improvements project.
— Reformer energy improvements and catalyst regeneration system upgrade.
— Retrofit of a Butamer Unit to Butadiene selective hydrogenation unit.
International Patent: PCT/GB95/02731 "Multi-Step Hydrodesulfurization Process"
United States Patent: 5958347 "Multi-Step Hydrodesulfurization Process".
Kolodziej, R. and Dutt, S., "Improve Direct Hydration Processes", Hydrocarbon Processing, Oct. 2001.
Kolodziej, R. and Tsai, M. J., "A Technology for Replacing MTBE", Hydrocarbon Processing, Feb. 2002.
Chicago Chem Consultants Corporation
14 North Peoria Street, Suite 2C
Chicago, Illinois 60607-2609
Phone 312-226-2436 · Fax 312-226-8886
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