Elyzaveta Y. Bateham

• Unit Operations: Dry Processing
• Spray drying (pressure and rotary wheel atomization), calcination, rotary dryers, sifting, Dust collection, Particle size distribution optimization, Dry milling airflow
• Wet Processing Experience
• Milling, Rotary drum/belt filtration
• Chemistry
• Silicasol binder, Solids Dispersion/coagulation, Alumina gel precipitation, Exposure to the crystallization chemistry, Ion exchange

Accomplishments:

• Streamlined PCG-2040 production to achieve stable production rates and ZSM-5 usage costs. Achieved a 10% sustained rate increase
• Raw material usages (e.g. boehmite AOH consumption reduction by 15% vs. std. at the end of 2006 and throughout 2007, SF5 filtration issues identified as the source of savings erosion associated with the boehmite consumption reduction)
• Process on-stream
• Active involvement in maintenance workflow to sustain process % on-stream Detailed downtime breakdown identified maintenance priorities and significantly reduced the recurrence of the top factors.
• Grade change optimization efforts (spray dryer inline mixer redesign to achieve 30% grade change idle time improvement, changeover guidelines and training)
• Area support in reducing the site’s environmental deviations (2007 vs. 1st Qtr. 2008)
• MS process optimization and development
• MS process debottlenecking – 10% sustained rate increase
• 5388 de-bottlenecking - 30% sustained rate increase
• PCG-2080/2050 product development support
• MS66 process development support
• Daily assignment area support (process operation & quality monitoring, troubleshooting, daily interaction with the operations personnel)
• Active participant in the deviations reduction team achieved >50% reduction in the environmental deviations
• Small capital project scoping/management (<$100K) – heat exchanger installation, pumping optimization, screening; process controls; DCS programming support

• Process support includes optimization projects (e.g. closing water mass balance, burner tuning, cost reduction), and managing additive production campaigns. Achieved a sustained 10% reduction in costly raw material consumption ($100K cost savings per 500-ton campaign compared with previous performance).

• Proposed improvements and designed experiments to optimize processes at the Middle Georgia facility; interfaced with the corporate R&D representatives, process and quality operators/supervisors, and material/equipment suppliers. Achieved a minimum 50% dispersant usage reduction or $300K cost savings as a result of the dispersant redesign project.

• Monitored, identified improvements and reduced cost of daily manufacturing of hydrous kaolin products; supported the production scheduling process; coordinated and led plant trials to manufacture newly commercialized products; revised site process flows for ISO compliance; conducted a “Process Mathematics” class for process laboratory technicians; supported the site-wide effort to streamline production data through conversion of operator logs to an automated electronic format.
• Projects (~ $400K collective identified and implemented savings):
• Product moisture control
• Spray dryer heat recovery – heat exchanger design & upgrade
• Apron dryer replacement evaluation
• Bulk loading process optimization
• Recovery project - identified true dryer and loading station yields and supported reporting dryer downtime and changeover losses to the logistics group to optimize the container delivery schedules
• Evaporator heat exchanger de-bottleneck, cooling water supply (chemical savings and service life extension)
• Product foaming issues (fuel savings)
• Wastewater treatment process pH control. Recognized for zero NPDS excursions in 2004