EDUCATION / LICENSING Curriculum Vitae Chad V. Mashuga mashuga@tamu.edu Ph.D. in Chemical Engineering, Michigan Technological University Dissertation Topic: Determination of the Combustion Behavior for Pure Components and Mixtures Using a 20-Liter Sphere Advisor: Dr. Daniel Crowl Graduation date: May 1999 B.S. in Chemical Engineering, Michigan Technological University Graduation date: May 1994 Licensed Professional Engineer, State of Michigan, 2004, Lic. no. 6201051925 PROFESSIONAL EXPERIENCE Texas A&M Department of Chemical Engineering (8/14-Present) The Dow Chemical Company Reactive Chemicals Group (11/06-8/14) Directed investigative research of plant explosions resulting in fundamental understanding of incident & mitigation of unrecognized safety concern for future production. Net impact tens of millions per year. Successfully procured funding and constructed dust hazard evaluation laboratory Successfully solicited and managed research/capital funds from 2007-2008 for establishing world class flammability testing center in Texas Designed & fabricated advanced flammability apparatus, currently utilized in improving the flammability model in several existing plants. Net impact is tens of millions per year Responsible for innovation, design and construction of Reactive Chemicals equipment capable of producing precise and accurate data for the development of reliable process models Developed and presented educational materials on gas, liquid and dust flammability and explosions for worldwide training of process engineers & scientists BASF Corporation - Research Services NAFTA (7/99-11/06) Director of experimental safety for BASF Corporation. Managed safety laboratory and staff, designed and constructed new equipment. Applied safety data during all phases of conceptual review, design and retrofitting activities Successfully acquired funding for the design & fabrication of an advanced dust explosion characterization device. Resulted in safer, faster & more consistent data collection Secured funding to update and automate flashpoint apparatus. This resulted in more consistent data and increased the efficiency of the laboratory staff Successfully assembled funds to establish a thermal separations research laboratory to validate process models and complement process simulation which resulted in several million in annual savings. Responsibilities included laboratory design, fabrication, construction, and supervision of staff
Managed startup funds to establish Process Simulation group. Developed BASF s largest and most complex plant simulations using ASPEN. Utilized simulation to identify bottlenecks and optimization opportunities with plant personnel. Initial success resulted in several other simulation projects Organized, developed and delivered training workshop for all process engineers on Physical Properties & Process Simulation. Provided thermodynamic theory for model selection, data validation, and hands on instruction of various simulation tools including ASPEN Wayne State University - Chemical Engineering (5/01 5/06) Consistently received positive teaching evaluations with recurrent student feedback stating courses were tough but fair Adjunct professor of chemical engineering. Course history is listed below: Fall 1997 Process Control & Simulation - MTU Summer 2001 Kinetics & Reactor Design Winter 2002 Thermodynamics Fall 2003 Process Dynamics & Simulation Winter 2003 Graduate Kinetics & Reactor Design Summer 2004 Material & Energy Balances Fall 2004 Process Dynamics & Simulation Winter 2004 Mass Transfer & Separation Processes Summer 2005 Material & Energy Balances Fall 2005 Process Dynamics & Simulation Winter 2006 Thermodynamics Permanent instructor for process dynamics & simulation 2003-06. Secured a donation from BASF for the development of process control laboratory. Designed & fabricated equipments allowing students hands on experience with plant scale control elements, instrumentation and controller tuning. Taught students to solve real process control problems in this laboratory with LabVIEW to gain understanding of control and data acquisition programming Member of the graduate thesis advisory committee, Wayne State University, 2004-2006 Member of the graduate thesis advisory committee, Michigan Technological University, 2002 TEACHING INTERESTS Chemical Process Safety Process Analysis & Design Process Control Chemical Reaction Engineering Transport/Unit Operations I & II Advanced Process Simulation Advanced Thermal Separations RESEARCH INTERESTS Flammability new experimental methods capable of producing quality flammability data for the development of predictive models at industrially relevant temperature, pressure, composition and turbulence. Includes methods for minimum ignition energy testing and its modeling. Applications results in energy and waste reduction, enhanced production and a realistic safety understanding. Application to traditional industrial flammability concerns as well as future applications including hydrogen. Dust Explosions advance current experimental methods capable of producing quality explosion data for dust and hybrid dust/flammable mixtures at industrially relevant temperature, pressure, composition and turbulence. Includes hybrid dust explosions and minimum ignition energy study. Utilize high quality data for development of predictive models to determine true dust hazards. Applications results in energy and waste reduction with enhanced production and safety.
Energetic Materials Testing develop a flexible, fast responding, cost effective testing range for the examination of energetic materials for government and industry. Capabilities could include: o Flexible testing capabilities for high energy materials and high risk reactions o Develop large scale equipments for the fundamental modeling of blast effects and overpressures on complex industrial structures, equipment & personnel o Large scale aerosol flammability testing o DOT & UN package classification testing Calorimetry develop new commercial calorimeters capable of fast, bench top or portable chemical compatibility testing. Develop new commercial calorimeter which has a combination of features not found in any current system. Develop new experimental methods and predictions capable of improving safe storage and aging dynamics and better models of lithium-ion cell safety & design Internal Combustion integration of hydrogen and other fuels in traditional and modified internal combustion engines. Safety and performance of blended fuels including bio-diesel and ethanol. PUBLICATIONS Diana Castellanos, Victor Carreto, Chad Mashuga, Sam Mannan, The Effect of Particle Size Polydispersity on the Explosibility Characteristics of Aluminum Dust, 9 th International Symposium on Hazards, Prevention, and Mitigation of Industrial Explosions, Cracow Poland, July 22-23 rd, 2012 Chad V. Mashuga, Automated Flammability Apparatus & Application, 2010 International Symposium, Beyond Regulatory Compliance, Making Safety Second Nature, Mary Kay O Connor Process Safety Center, College Station, October 2010. Chad V. Mashuga, Daniel A. Crowl, Derivation of Le Chatelier s Mixing Rule for Flammable Limits, Process Safety Progress, August 2000. Chad V. Mashuga, Determination of the Combustion Behavior for Pure Components and Mixtures Using a 20-Liter Sphere, Ph.D. dissertation, Michigan Technological University, Houghton Michigan, May, 1999. Chad V. Mashuga and Daniel A. Crowl, Problems with Identifying a Standard Procedure for Determining K G Values for Flammable Vapors, International Symposium on Hazards, Prevention, and Mitigation of Industrial Explosions, Schaumburg, IL, September 21-25, 1998 and published in Journal of Loss Prevention, Vol. 13, pp 369-376, 2000. Chad V. Mashuga and Daniel A. Crowl, Flammability Zone Prediction Using Calculated Adiabatic Flame Temperatures, AIChE 33 nd Loss Prevention Symposium, Houston, March 14 th -18 th, 1999 and published in Process Safety Progress, Vol. 18, No. 3, 1999. Chad V. Mashuga and Daniel A. Crowl, Application of the Flammability Diagram for Evaluation of Fire and Explosion Hazards of Flammable Vapors, Presented at the AIChE 32 nd Loss Prevention Symposium, New Orleans, March 11 th, 1998 and published in Process Safety Progress, October, 1998.
PUBLICATIONS IN PROGRESS Diana Castellanos, Victor Carreto, Chad Mashuga, Remi Trottier, Andres Mejia, Sam Mannan, The Effect of Particle Size Polydispersity on the Explosibility Characteristics of Aluminum Dust, Accepted and in review, Journal of Powder Technology. Diana Castellanos, Victor Carreto, Chad Mashuga, Trygve Skjold, Sam Mannan, Construction of a 36L Dust Explosion Equipment and Comparison of Turbulence Flow Field with a Standard 20L Dust Explosion Vessel. To be submitted to the Journal of Loss Prevention in the Process Industries. Diana Castellanos, Andres Mejia, A. Diaz, Victor. Carreto, Z. Cheng, Chad Mashuga, Sam Mannan, Influence of Particle Size and Crystalline Level on the efficiency of Dust Explosion Inhibitors. To be submitted to the Journal of Powder Technology. SELECTIVE INTERNAL REPORTS Chad V. Mashuga, Method for Measurement of VSP Head Void Space Volume, Internal Report CRI-8627265, August 2011. Chad V. Mashuga, Reaction of HITEC Salt and Carbon Residue from Acrylic Acid Production In a Modified VSP, Internal Report CRI-7896527, March 2011. Chad V. Mashuga, Molten HITEC Salt & Carbon Residue Absorption Test, Internal Report CRI-8636133, November, 2010. Chad V. Mashuga, DOW s New Acrylate Production Flammability Model, Internal Report, The Dow Chemical Company, Freeport TX, June, 2009 Chad V. Mashuga, Automated 5L Flammability Apparatus Development, Internal Report, The Dow Chemical Company, Freeport TX, December, 2008 Chad V. Mashuga, Two-Phase Relief Design: Method for Determining Reaction Kinetics from Calorimeter Data, Internal Report, The Dow Chemical Company, Freeport TX, September, 2008 Chad V. Mashuga, Polyol Reactor Emergency Relief System Simulation & Design, Internal Report, BASF Corporation, Wyandotte MI, March, 2006 Chad V. Mashuga, Automation of a 20L Dust Explosion Apparatus, Internal Report, BASF Corporation, Wyandotte MI, January, 2006 Chad V. Mashuga, Jan Anushcek, Tom Komjathy, Scale-Up of Distillation Columns, Internal Report, BASF Corporation, Wyandotte MI, 2002 Chad V. Mashuga, ASPEN Simulation of Acrylic Acid Production, Internal Report, BASF Corporation, Wyandotte MI, February, 2001 BOOK CONTRIBUTIONS Chad V. Mashuga, Revisions and update to Chapter 8 on Case Studies, American Institute of Chemical Engineers Guidelines for Chemical Process Quantitative Risk Analysis, 2001. Chad V. Mashuga, Tables and Figures, Understanding Explosions, Center for Chemical Process Safety, American Institute of Chemical Engineers, New York, NY, 2003.
SELECTIVE PRESENTATIONS Chad V. Mashuga, Researching Off Color Particles in Dow Cellulose Production, Cellulose Manufacture Technology, The Dow Chemical Company, Freeport Tx, and Zwijndrecht Netherlands, April, 2013 Chad V. Mashuga, Current Findings of the Root Cause Investigation of the Acrylic Acid Production Incident, The Dow Chemical Annual Technology Center Leaders Meeting, Freeport, TX, April 2011. Chad V. Mashuga, Flammability Basics, Pune India Technology Center, The Dow Chemical Company, Freeport, TX, October, 2008. Chad V. Mashuga, New Developments in Flammability Testing within The Dow Chemical Company, presented to all Global Technology Centers, The Dow Chemical Company, Midland, MI, February, 2007. Chad V. Mashuga, Introduction to Flammability, presented to all Global Technology Centers, The Dow Chemical Company, Midland, MI, February, 2007. Chad V. Mashuga, Experimental Safety in the Process Industries, presented to the Wayne State University, Department of Chemical Engineering, Senior Design Course, Detroit, MI, April, 2006. Chad V. Mashuga, Physical Properties & Process Simulation, presented to the Process Engineering Group, BASF Corporation, Freeport, TX, September, 2004. Chad V. Mashuga, Process Simulation in the Chemical Industries, presented to the Wayne State University, Department of Chemical Engineering, Senior Design Course, Detroit, MI, May, 2002. Chad V. Mashuga, Application of Thermal Separation Theory & Process Synthesis in BASF NAFTA, presented at the BASF Thermal Separations Seminar, Galveston Island, Tx, March 27-29 th, 2001. Chad V. Mashuga, Physical Properties & Simulation, presented at the BASF Thermal Separations Seminar, Galveston Island, TX, March 27-29 th, 2001. Chad V. Mashuga, Problems with Identifying a Standard Procedure for Determining K G Values for Flammable Vapors, presented at International Symposium on Hazards, Prevention, and Mitigation of Industrial Explosions, Schaumburg, IL, September 21-25, 1998. Chad V. Mashuga, Application of the Flammability Diagram for Evaluation of Fire and Explosion Hazards of Flammable Vapors, presented at AIChE 32 nd Loss Prevention Symposium, New Orleans, March 11 th, 1998. ORGANIZATIONS Adjunct Faculty Texas A&M dept. of Chemical Engineering (07/13 8/14) Texas A&M MKOPSC Technical Advisory Committee (04/11 Present) ChemE car JSA reviewer & on site inspector (02/08 Present) Explosion Research Cooperative Baker Risk Eng. San Antonio Tx (01/07 Present) ASTM International member (12/04 Present) Adjunct Faculty Wayne State Univ. dept. of Chem. Engineering (05/01 5/06) Safety and Health Division 11a executive committee (09/02 Present) AIChE National member (01/93 Present)
AWARDS Dow Chemical Tech Center Award Optimization of Aromatics Catalyst Sulfiding, May 2014 Dow Chemical Tech Center Award Nitrate Salt Explosion Risk Reduction, Sept 2012 Dow Chemical Carat Award Acrylates Incident Research, Sept 2011 Dow Chemical Carat Award Establishing of a World Class Flammability Lab, July 2007 Dow Chemical Carat Award Organizing Global Flammability Training, February 2007 William H. Doyle Award, AIChE Loss Prevention Symposium, March 2000 Outstanding Graduate Research Award, Michigan Tech. Univ., May 1996 Marshall & Nellie Alworth Engineering Scholarship, 1991-1999