Mark S. Karrs has extensive experience in pyrolysis technology, with emphasis on furnace design, project management, procurement, and construction planning and oversight. Over a 25+ year career, he has executed all phases of ethylene plant design, from the conceptual to startup and troubleshooting. He has worked on dozens of expansion studies and revamp/upgrade projects associated with existing units.
Mr. Karrs gained his experience as a Process Design Manager for Lummus Technology, and as a Project Manager and most recently as Director of Engineering for the Lummus Heat Transfer division. Selected projects include:
- Managed process design effort for the world’s first Million metric ton per year liquids cracker, the largest single train Ethylene Plant in the world at the time.
- Responsible for the development of the most recent radiant coil technology, as well as the design of all pyrolysis modules for all proposals and projects.
- Proposal preparation and project execution for an Ethylene unit reconfiguration that significantly reduced energy use and achieved a 92% reduction in NOx via SCR retrofit.
- Managed a 3 heater addition for an olefins complex that included design of all piping, instrumentation, electrical and civil requirements plus support to client’s procurement staff with erection subcontracts.
- Design of a hot oil heater, circulating pumps, heat exchangers and all related piping, instrumentation and electrical for an overseas client.
- Proposal preparation and execution for the addition of one new fired heater and revamp of nine existing fired heaters at a 40 year old pyrolysis facility.
- Managed contract to supply engineering and materials for hydrogen reformer heater and three smaller heaters for export to a South American company.
- Led investigations and personally performed troubleshooting on operating heaters to help clients meet performance objectives.
Mr. Karrs holds a BS in Chemical Engineering from Purdue University and holds two patents in the area of heat transfer equipment design. He has participated in a wide variety of conferences related to ethylene plant design, and has authored technical articles associated with fired heater design, maintenance, retrofits, coil balancing and NOx reduction.