Chemical Engineering Portfolio Pre-1994

1979 -- 1993 KODAK AUSTRALASIA PTY LTD

1991 -- 1993 Supervisor, Engineering Maintenance

Responsible for all maintenance functions in the Emulsion Production and Film Coatings Departments. Implemented the initial stages of a Total Productive Maintenance program to increase equipment and process reliability. Participated in management teams to generally improve the department’s performance. Team leader in the implementation of TQM and AS3902 accreditation for the maintenance section. Directly supervised a maintenance staff of approximately 20 people ranging from computer technicians, instrument fitters, electricians, fitters, plumbers and T.A.’s. Participated in the introduction of multi-disciplined trade skills as part of the award restructuring program.

MAJOR ACHIEVEMENTS

Introduced valve maintenance program on P231 Emulsion Make and Ultrafiltration plants. US representatives acknowledged improved performance of plant as determined from process performance data. Eliminated chronic problem on Rotaire steam coil. Coil required rewelding every two weeks. Redesigned steam and condensate piping and eliminated problem. Replaced in line s/s ROD water calorifier -- a chronic maintenance problem due to continual leaks -- with ring main system from Chem Prep hot ROD tank. Also provided more reliable supply. Upgraded and purchased many tools to improve quality and efficiency of maintenance department. Greatly improved morale of maintenance personnel.

1979 -- 1991 Project Engineer/Sen Project Engineer

Conceptual design, project estimates, preparation of reports requesting capital funds, project feasibility studies, setting and monitoring of costs and schedules during all phases of the project i.e. design, construction and commissioning to ensure adherence to specifications, schedules and cost. Preparation of operating and maintenance documentation and assistance in operator and maintenance training.

MAJOR PROJECTS

Emulsion Manufacturing Plant - P231 Program:

Project manager for implementation of a new photographic emulsion manufacturing facility. Eleven functionally equivalent plants were built around the Kodak world to reduce product variability from site to site. My role was as Australia’s representative on the world wide design team and as local project engineer (this also included a large utilities upgrade program). My involvement in the project included three separate trips to Kodak plants in Canada and USA. The project was implemented stage wise from 1984 to 1986 with some further upgrades in 1987. The total cost of all associated projects was $8.4M and the plant has been producing 100% of Kodak Australasia’s photographic emulsions since 1987.

Photochemical Mixing Tank:

Installation of a 10,000 litre mixing vessel mounted on load cells with all associated services. Tank construction -- FRP lined with PVDF. 1991. Cost $180K.

Microcrystalline Dye Dispersion Facility:

Provision of small jacketed kettles, specialised high shear agitation and intermediate packout equipment for this photographic emulsion ingredient. 1991. Cost $100K.

Factory Air Compressor:

Project management of compressed air service upgrade for the factory including an additional 370 L/s compressor, new cooling water system, air drier and distribution main header. 1990. Cost $600K.

Silver Recovery:

Installation of two rotary vacuum drum filters to recover colloidal silver from photographic emulsion waste and wash waters. The filters replaced a solid bowl centrifuge and resulted in 100% compliance of silver discharge to sewer and an annual cost savings in excess of $500K. 1989. Cost $550K.

Statutory Compliance/Bulk Tank Installations:

Implementation of a number "compliance projects" (i.e. Dangerous Goods, EPA, Melbourne Water etc.), involving new tank installations, tank replacements and upgrades, bunding and spillage control, solvent storage and handling, waste minimisation and pH control of effluent. 1988 -- 1991. Total Cost $1M.

Bottle Filling Line:

Installation of a photochemical bottle filling and capping line. 1990. Cost $600K.

Nitric Acid Distillation and Bulk Storage:

Design and project management of a nitric acid distillation unit and bulk storage vessel to produce and store high purity acid from commercial grade. Principal materials of construction were glass, titanium and PVDF lined FRP. 1987. Cost $140K.

Silver Nitrate Plant:

Process design and project management of a silver nitrate production plant using innovative design concepts not used elsewhere in the Kodak world. 1981. Cost $850K. A further upgrade in 1984 Cost $250K.

Silver Refining:

Assisted in the development and design of an in house electrolytic silver refining facility to produce bullion at 99.99% purity. 1980. Cost $250K.

Anodising Plant:

Implementation of a hard anodising plant to anodise film transport rollers as part of a major coating track upgrade. 1980. Cost $100K.