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Malcolm E Flint has over 30 years of engineering and management experience in the refining and petrochemical industries, based on his long-term careers first with Gulf Oil Chemicals, then with Sunoco, and as an independent consultant. His experience includes operations, process troubleshooting, process safety, and engineering management. Selected positions and accomplishments:

Operations Manager, Sunoco Refinery, Marcus Hook, PA

  • Increased crude throughput from nominal 175 B/SD to 200MB/SD by operational changes and small capital investment
  • Increased FCCU throughput from 90 MB/SD to 100MB/SD by operational changes

Refinery Manager, Sunoco Refinery, Marcus Hook, PA

  • Managed 175 MB/D integrated refining, petrochemical, lube complex
  • Managed integration of adjacent acquired petrochemical complex into the refinery.

Director Engineering Services, Refining Division, Sunoco, Philadelphia, PA

  • Managed Sunoco's engineering personnel providing expert technical support to refineries.
  • Managed front end engineering, detailed design, and construction for aromatics extraction expansion and solvent change, propylene splitter using heat pump technology, benzene NESHAP controls at 5 refineries, crude vacuum tower revamp 
  • Implemented partnering agreements with an engineering company (Fluor Daniel) and with a construction management company (MK Ferguson) to handle the large increase in projects
  • Managed design and implementation of (OSHA) process safety management (PSM) program throughout Sunoco’s refining system

Consultant

  • Developed startup plan following change to a new catalyst at Sunoco's Philadelphia Refinery Cumene plant. This change reduced time from mechanical completion to on-spec product from previous industry best of 10 days to 5 days and significantly expanded production.
  • Led major process incident investigations, identifying root cause(s) and developing recommended corrective actions
    • Major release of oily catalyst from FCCU
    • Absorber explosion
    • Repeated superheater failures at CO Boiler
    • Discharge of excessive amounts of oil into waste water treating system
  • Serve as a member of the Sunoco corporate refinery and petrochemical PSM audit team

Mr. Flint holds a BS in Chemical Engineering from Princeton University and has completed several management courses.

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  • DAVE VAHLSING

    David H. Vahlsing has extensive petroleum industry and consulting experience, with emphasis on process design, technology evaluation, project scoping and oversight of project teams. Dave developed and applied his professional expertise at various locations within Sunoco, Inc and subsidiaries, including the Toledo refinery, the Central Engineering Department, the Toronto headquarters of Suncor and in R&D, and since with HEA and Becht Engineering. He was the Central Engineering expert in HF Alkylation, Isomerization, treating of crude and refinery projects where he also supervised the Process Design and computer support groups. He has evaluated many licensed technologies for use in Sunoco’s refinery…
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    • Refining&Coke

  • HARRY A. ADAMS

    Harry A. Adams worked for BP Oil (formerly The Standard Oil Co. of Ohio)  in R & D for many years and served as  Process Technology Manager for BP's worldwide petroleum coking operations. Following his retirement from BP, he has been a coking consultant serving many clients throughout the USA as well as in Canada, Indonesia, Kuwait, Brazil, India, Switzerland, and Argentina. Successfully supported a client that does coke cutting on a contract basis in resolving a performance dispute between the client’s customer and the client. An excessively hard coke was unacceptably increasing coke cutting time. The issue was quickly…
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  • JOHN D. BARRY, PE

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  • JOSEPH C. BELL, PhD

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  • MANOJ V. BHINDE

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  • FREDERICK W. CAMP

    Frederick W. Camp, a founding principal of HEA, has technical, operations, and management experience in chemical engineering. A seasoned generalist, Dr. Camp's forte is application of engineering theory and principles to solving practical development and operational problems. His special areas of expertise include process development, design, and scaleup; oil sands extraction and processing; economic analysis; design and analysis of experiments; mathematical modeling; and strategic technology planning. He joined the R&D Department of Sunoco, Inc. in 1962 and advanced through positions of increasing managerial and technical responsibility over the succeeding 30 years, retiring in 1991. During 1964-5, he was appointed group…
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    • Chem&BioFuels
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