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Design/Build/Outsourcing Projects
Robert Freeborn
Listed below are some of the various projects from simple outsourcing of
materials to full scale projects to designing, building, owning, operating and
maintaining very detailed systems.
1. Ford, Lorain Assembly (1991) – Chrome Destruction process (D/B/O/M).
2. Rouge Steel/Ford (1987) – Automated Outfall Control System (D,B)
3. WCI Steel (1990-1995) – Designed cascading blowdowns (4 systems), solids
handling (clarification), Chemical Storage/Handling for 5 systems for a new
continuous caster. (D/B/M)
4. Republic Engineered Steel (1996) – Re-designed WWTP including new
filtration system First Nalco/US Filter “TWO” project (D/B/M)
5. Republic Engineered Steel (1997) – Complete water pretreatment/Filtration
system for new continuous caster. (D/B/O/M)
6. British Paperboard, England/Scotland (1999) – Developed and implemented
complete Facilities Management program for Chemicals, Industrial Services and
maintenance. (D/O/M)
7. Shanghai General Motors (1999) – Collaborated with PPG to provide facilities
management for the new SGM plant in China (D/O/M)
8. Chrysler, Curitiba, Brazil (2000) – Designed water pretreatment, storage,
filtrations systems for a new assembly plant in Brazil with PPG. (D/M)
9. GM, Tonawanda (2001) – Collaborated with York and Praxair for a new
chiller/cooling system for the Tonawanda Engine plant (D/B/O/M)
10. IPSCO, Montpelier, Iowa (2001) – Proposed full takeover of the utility systems
(river water clarification, pretreatment, filtration and discharge) for a mini-mill.
(Operate and Maintain)
11. Bethlehem Steel, Sparrows Point (2000) – Collaborated with Infilco Degremond
to re-design the final discharge system (Humphrey’s creek) for the entire steel
mill. (D/B/O/O/M)
12. American Crystal Sugar, Fargo, ND (2001) – Developed and implemented a
facilities management program for chemicals, industrial services and operations
of chemical systems for the sugar industry (Design/Operate/Maintain)
13. Ford Motor Company (2001-2008) – Facilities Manger (Tier 1)
Bio/Technical Achievements
Robert Freeborn
Listed below are some of my achievements in troubleshooting and solving technical
issues with utility systems, audit facilities to prepare O&M recommendations, and be part
of teams to correct operational issues be it mechanical of chemical in nature. I have
strong knowledge of water system from municipal to middle market and even heavy
industrial settings, using creative methods (both mechanical and chemical) to overcome
obstacles in industrial environments. These are not all the technical situations that have
been encountered in industrial applications but give a flavor of the variety of problems I
have encountered and some “out of the box” thinking required to solve these problems.
Steel
1. WCI Steel – Warren, Ohio (1993-1996)
- Was the lead water consultant for the installation of a single slab, continuous
caster. The utility support system included five separate and distinct water
systems for: Makeup Water, Mold water (100,000 gal. system), Machine Water
(250,000 gallons), Spray Water (350,000 gallons) and Vacuum Degasser water
(100,000 gallons). Our creative Amiad strained makeup water took solids down to
10 microns in size allowing for direct use as makeup for the systems. Mold water
was softened to prevent scaling in the molds, machine water was conditioned to
cool bearings, rolls and heat exchange equipment, spray water was treated for
Hydroflouric acid generation and system wide corrosion, and the vacuum
degasser water treated for solids and scale inhibition. Process Consulting
- The biggest success was designing in cascading blowdown’s for one system to
another with compatible chemistries to render only 100 gallons per minute
blowdown, discharged from the facility. Normal caster systems would be
anywhere from 500-1000 gallons per minute. Designed in, up-front cost savings.
- A challenge rose when mold powders changed, causing high hydrofluoric acid
generation in the spray water. To prevent iron hydroxide from forming with the
addition of caustic, a stoicimetric procedure was developed to add sodium
bicarbonate (baking soda) as the alkalinity replacement, stabilizing levels,
preventing system wide corrosion and eliminating the precipitation of iron
hydroxide. Problem Solved
- The mold powder also had a secondary impact on the machine operation. This
was and is a widespread problem that continues in continuous casters. Calcium
fluoride formed as a result of temperature and evaporation causing hoses to break,
material buildup and loss of heat transfer. A simple and inexpensive chemical
application stopped the deposition immediately. Problem Solved
2. Republic Engineered Steel – Canton, Ohio (1994-1995)
- Spearheaded the first outsourcing project between US Filter and Nalco to design,
build, and operate a new water treatment facility fitting into the existing footprint.
The existing system could not handle the oil and grease or solids loading and a
filtration process was developed to meet all discharge permits.
- Consulted on a new water facility for a 4 strand bar caster working directly with
the engineering firm in Italy to meet water quality requirements for and EMS
system and high quality mold water. Process Consulting
3. IPSCO Steel – Davenport, Iowa (2000-2001)
- Led project team to determine scope and operating plan for all the water and
utility systems at IPSCO Steel. This did not include the electrical distribution
system. All equipment was evaluated, maintenance records reviewed, repair and
replacement costs determined and improvements in the water handling process in
the mill investigated to bring water quality up to standards. System involved were
an electric furnace operation, continuous caster, oily water separation equipment,
and hot and cold rolling mills. Of particular problems were contaminated makeup
water from the Mississippi, combined rolling mill/caster spray water systems and
capacity issues requiring wells. Process Consulting
4. Rouge Steel – Dearborn, MI (1984- 1990)
- Provided technical support to revamp the treatment and operating conditions for
the terminal treatment facility for Rouge Steel and Ford Dearborn Assembly
Plant. The system produced 1000 gallons per minute through two (2) 1,000,000
gallon clarifiers and then used a 5 million gallon settling basin for secondary
treatment. Compliance issues were a monthly event and were eliminated with
creative rerouting of water, automation and upstream chemical applications.-
Problem Solved
- Serviced the Rouge powerhouse for three years improving the pretreatment
system to reduce chemical costs $250,000 per year. Four 1800 lb. Boilers and
three 250 lb boilers produced steam for turbo blowers, electric turbines service
steam for then entire Rouge complex including Double-Eagle Steel. The boilers
were coal fired, tangential gas burner retrofitted experiencing tube failures due to
long term overheating. A tube preventive replacement program was initiated to
prevent catastrophic failures. The combination of improved water quality,
increased system monitoring and preventive tube failures, allowed the facility to
operate until it’s final end in 2000. – Problems Solved, Reduced Operating Costs
- Blast Furnace discharge problems with ammonia almost caused a plant shutdown.
Breakpoint chlorination was used for ammonia destruction but incoming
ammonia caused by high coke ammonia levels could not be addressed with
current equipment. The source was identified, a team I was part of, was sent to
New Boston Coke to identify the problem and recommend a fix. Evaluating the
quenching process and byproducts treatment, a fix was implemented, ammonia
levels came back in line and water discharge could resume. Problem Solved
- Provided technical assistance in the design and construction of a new two strand
continuous caster in 1986-1988. Innovative technologies, automation, material
handling and equipment recommendations provided state of the art conditions for
product quality. Working with fifteen (15) Parkson upflow filters, two 50,000
gallon clarifiers and associated heat exchange equipment, water quality remained
a constant for optimal operating conditions. Designed in Cost Control
- Was part of a technical team from Rouge, US Steel and Nalco to evaluate the
utility problems at Double Eagle Steel Galvanizing Line in Dearborn, MI only
two years after startup. Changes in piping, steam requirements, equalization and
treatment systems allowed the plant to meet zinc discharge limits continuously
below 0.07 ppm. Problem Solved
5. US Steel - Great Lakes Works [Great Lakes, National] (1982 to present)
- Provided water consulting for the installation of the #2 caster and vacuum
degasser in 1988. Process Consulting
- Participated in a task force to troubleshoot the water systems in 1996. Severe oil
fouling, filter failure and lost production prompted focus on changing piping and
control systems. Process Consulting
- Presented an outsourcing project for replacement of the disk filters at the Zug
Island, blast furnace recycle system with centrifuges. This project would be from
design, to build, own and maintain the facility. Failures in “asset management”
companies such as Enron, postponed decisions to outsource and drove the process
internally. Process Consulting/Outsourcing
- Assumed technical responsibility for the #2 caster water systems in November
2008. Technical problems associated with severe structural corrosion (over 15
years) attributed to Hydrogen Fluoride form mold powders and numerous bearing
failures (over 10 years) prompted immediate investigation. Online corrosion
monitoring with system chemistry determine the cause of the corrosion (alkalinity
depression system wide) and recommendations were made to adjust system
chemistry to prevent further system wide impact. Bearing failure analysis of
deposits in the bearings led to external causes and procedures for cleaning and
external contamination were immediately put into practice. Problems Solved in
less than one month.
Refining
1. Marathon, Detroit - Identified heat exchanger failure form analyzing condensate
for organics. Once sample hit ambient air, the organic would flash off dropping
condensate pH almost to a pH of 4.0. To prevent flashing and false pH impact,
cooled condensate was passed through an analex cartridge, sealed and the resin
was tested for organics. The result was the presence of hexadecane, cyclopentane
and other friedl crafts breakdown products of benzene, toluene and xylene
determining the failed heat exchanger. Problem Solved
2. Pennzoil, Pennsylvania - Isolated the foulant on filter media causing
pretreatment fouling and system shutdown. Complete pretreatment fouling was
caused by the many oxidations states of manganese and proper chemical
treatment before the filters remedied the problem. Problem Solved
3. Marathon, Detroit - Feedwater line corrosion after the deaerator feeding high
pressure steam generators for the crude unit indicated leaks in the feedwater line.
Detailed oxygen testing concluded deaerator failure itself prompting a premature
crude unit shutdown and subsequent prevention of catastrophic failure in the unit.
Problem Solved
Pulp and Paper
1. British Paperboard (London, England and Aberdeen, Scotland)
– Personally identified the cause for loss of the biofilm on an effluent treatment
system four weeks after the event occurred. Plant personnel and water experts
were baffled but investigation of plant logs, maintenance records and inspection
of equipment led to the conclusion that several failed bearings generated
particulate metallic copper in enough quantities to “poison” the film. The film
was cleaned without analysis, the bearings replaced and film was reestablished
without determination of cause. Problem Solved
2. Stone Container, Coshocton, OH
– 1800 pound boiler feedwater capacity problems were determined to be result of
short runs with the demineralizers caused by fluctuating incoming hardness,
alkalinity and pH. The cause was incomplete cold lime softening by the city and
steps were made to consult with the city to produce consistent water quality for
the paper mill and prevent “red” water throughout the city of Coshocton.
(municipal) Problem Solved
3. Tenneco, Red Bluff, CA (Egg carton plant)
– During a chemical review and plant walk-through to evaluate a chemical
management program, a mechanical recommendation was made to spray calcium
stearate only on egg cartons passing through the production stream. The micro-
switch recommendation saved the customer over $20,000 per year in calcium
stearate loss. Problem Solved and Reduced Operating Costs
Pharmaceutical
1. Upjohn, Kalamazoo, MI
– Severe internal chiller fouling slowed the production of Minoxidil (Rogaine).
Complete system surveys (flow, temperature, heat exchange, pressures) identified
low flow conditions and the heat exchangers were repiped to increase cooling
flow required for product production. Problem Solved and Product Quality
Improvements
2. Upjohn, Kalamazoo, MI
– Cyanide contaminated waste was being deep well injected and the facility wanted
to investigate methods to prevent the practice. Third party expertise was arranged
to treat the waste stream through mechanical and chemical means and stopped the
deep well injection. Environmental
Automotive
1. Ford, Lorain Assembly (1991)
– Designed, constructed and installed a point source, “chrome destruction” process
for the pretreatment line. Typical waste water volumes of over 500,000 gallons
per day were typical to reduce hexavalent chrome to the trivalent form in existing
water treatment design. The “point source treatment” system was designed, built
and installed according to my specifications utilizing two pH control systems and
automatic chemical treatment (sodium bisulfite) for 50 gpm of concentrated
chrome solution. This assured that the chrome was reduced resulting in dramatic
operational cost reductions for acid and caustic typically used to drop pH below
4.0 and then raise the 500,000 gallons up for solids precipitation and discharge.
Improved Process, Reduced Operating Costs
1. Ford Corporate
– Participated in corporate monthly meetings (with Betz, Nalco and Drew) in the
early 90’s as part of the Total Fluids program to standardize all water treatment
parameters, limits, acceptable products and performance criteria for assembly and
powertrain facilities. Process Consulting
2. Ford, Avon Lake Assembly
– Identified a “Weak Link” in the weld water system allowing particulate iron to
foul welder tips. Mechanical changes and operational changes were recommended
to prevent the problem from reoccurring saving loss of tips, downtime, and
improvement in product quality. Problem Solved and Reduced Operating Costs
3. Ford, Van Dyke Transmission (Elimination of a Hazardous Waste)
- A waste stream containing lead (lead dust from machining) was disposed through
a hazardous material handling company prior to review. Discussing the waste
with metals recovery suppliers, the waste was able to be rerouted and turn it into a
raw material. Environmental
4. Ford, Van Dyke Transmission
- “Best Practice” awarded in 2006 for Trash to Energy. Facility received 2
environmental awards in 2007 for landfill avoidance. 2007-2008 landfill
avoidance - 81% with only 4 waste streams left to achieve 100%. Environmental
activities key for Michigan Corporate Citizenship award for 2007 and Ford
Environmental awards for 2006. Environmental
5. Ford, Van Dyke Transmission
- The waste water treatment plant operations and cost were scrutinized to reduce or
even eliminate the dependence on the facility. Water flows were dramatically
reduced due to new machining and plant downsizing. Potential operating savings
of $500,000 per year were targeted. Ford corporate delegated further investigation
but has been tabled due to reduced internal resources. Process Consulting
6. Ford, Ohio Assembly Plant
– Waste from van production was estimated at a tare weight of 80 #/unit for new
Econoline line. Offsite sequencing using my data reduced tare to 61 #/unit in 6
months. Continued mapping through 2006 -2007 further reduced tare to 55 #/unit.
Waste minimization initiatives further reduced tare to 50.64 #/unit. Total tare
reduction in 2 years – 36.25% Environmental/Cost Reduction
7. GM, Lordstown, Assembly
– Determined the cause of compressor failures due to scale formation in the heat
exchangers. The use of a carbamate based biocide, with controlled feed formed
calcium carbamate. Changeover to the proper biocide, control of conductivity and
blowdown remedied the problem. Problem Solved - Process Improvement
8. GM, Lordstown, Assembly
– “White rust” problems with aluminum heat exchangers with non-treated water
prompted online evaluation of products to treat multi-metal system. Proper
control, chemical treatment and blowdown remedied the problem. Problem
Solved
9. GM, Lordstown, Assembly
– RO fouling for “ELPO” makeup and subsequent replacement of the RO
membranes drove investigation into the proper chemical and mechanical changes
to pretreatment before the RO’s. The system needed to be redesigned and fit into
the existing space to provide for filtration and dechlorination prior to RO
treatment. Problem Solved
10. GM, Lordstown, Assembly
- Paint stack failures necessitated the investigation of corrosive water on stack
joints. A sampling station was erected and stack tests were conducted to
determine the corrositivity of the water. It was determined that the cause was two
fold. The first, booth balance and the second, stack metallurgy. The stacks were
designed to be stainless but cost concerns settled on mild steel without joint
protection causing the failure at the stack joints. Process Consulting - Problem
Solved
11. Ford, Valencia, Spain
– Review of the waste treatment plant identified problems with proper application
of chemical treatment for a continuous process. 95% of Fords’ plants are designed
as batch processed while Valencia used the same treatment chemicals and
application technology causing high variability and upset conditions. Mechanical
and chemical changes were recommended and plant upsets were eliminated.
Process Consulting
12. GM, Lordstown Assembly
– Post precipitation problems existed with the discharge filters due to over addition
of lime in the precipitation process for pretreatment wastes. New pH guidelines,
alternative chemical recommendations and improved testing eliminated the
problem and cost to re-bed the filters. Process Consulting
13. Ford, Lorain Assembly (Boiler Failures)
– Ford had shut down the on-site boilers and opted for Clayton Steam generators.
The steam generators (6) took plant condensate and makeup to provide necessary
process steam. After six months, three boilers experienced catastrophic failures
due to high condensate iron levels. Ford legal and the tier 1 total fluids manager
blamed the water treatment company but deep dives into operating records, water
sampling, operating recommendations and design criteria indicated poor system
design and subsequently Ford accepting responsibility. Process Consulting
14. Ford, Lorain Assembly
– The city of Lorain cited Ford for discharging untreated waste directly into the
municipal system. Upon investigation and chemical demonstrations, the
precipitation of pretreatment waste was from an operator discharging a 250,000
gallon batch without treatment and subsequent precipitation of materials in the
municipal plant overloading the facility. Ford legal accepted fault for the
untreated discharge based on pH logs and test demonstrations. Process
Consulting
Industries, Corporations, Facilities and Systems
Listed below are the corporations and facilities that I have called on, serviced or managed
throughout my career. It is not complete though indicates the various industries and
applications I have encountered. Some of the facilities may now be renamed, bought out
by other entities or even torn down.
Steel
International (Mini and Integrated)
- AHMSA Steel, Mexico
- Sidor Steel, Venezuela
- Hamburg Steel Works, Germany
- Badische Steel Works, Germany
- Klockner Works, Germany
- Thyssen-Krupp, Germany
- British Steel, England (Teeside, Sheffield, Scunthorpe)
- Allied Steel, Cardiff Wales
- Fiat, Belo Horizonte, Brazil
- Firth Brown, Sheffield, England
- Avesta Steel, Sweden
- Fagersta Steel, Sweden
- Creusot Loire Steel, France (2 mills)
- Voest Alpine, Austria
- Bolzano Steel, Italy
- Beltrame Steel, Italy
- Usinor, Belgium/France
- New Holland Italia, Italy
- Magneti Marelli, Italy
- Caffaro, Italy
Domestic (Mini and Integrated, Aluminum, Specialty)
- US Steel (Baytown, Gary, Great Lakes, ET, Fairless Works, Lorain and
corporate)
- Bethlehem Steel (LA, Seattle, Burns Harbor, Sparrows Point)
- LTV Steel (Cleveland, Chicago and corporate)
- AK Steel (Middletown, Ashland)
- Armco Steel (Butler, Kansas City, Houston, Mansfield)
- North Star Steel (Minn./St. Paul, Wilton, Monroe)
- WCI Steel, Warren, Ohio
- Republic Engineered Steel, Canton, OH
- Interlake Steel, Wilder, Kentucky
- LaClede Steel, Alton, Illinois
- Lukens Steel, Coatesville, PA
- Green River Steel, Owensboro, Kentucky
- Birmingham Steel, Birmingham, Alabama
- MacSteel, Jackson, Michigan
- Georgetown Steel, Beaumont, Texas
- Nucor Steel, Norfolk, Nebraska
- Newpoot, Steel, Newport, Kentucky
- Raritan Steel, Raritan, New Jersey
- Chaparral Steel, Midlothian, Texas
- Ipsco Steel, Muscatine, Iowa
- J&L Specialty, Detroit, Michigan
- Washington Steel, Massillon, Ohio
- Rouge/Severstal, Dearborn, Michigan
- Timkin, Canton, Ohio
- Special Metals, Canton, Ohio
- Brush Wellman (Copper/Beryllium), Elmore, Ohio
- Alcoa (Cleveland, Newburgh, Massena and corporate)
- Double Eagle Steel (Galvanizer), Dearborn, Michigan
Pulp and Paper
- Stone Container, Ohio
- Port Huron Paper, Michigan
- Crown Vantage Paper, Michigan
- Tenneco Packaging, Red Bluff, California
- Weyerhaeuser, Washington
- Grief Brother’s, Ohio
- Willamette, Beaverton, Oregon
- PCA, Rittman, Ohio
- Weyerhaeuser, Minneapolis/St. Paul
Refining
- Marathon, Detroit, Michigan
- BP, Toledo, Ohio (and corporate)
- Sunoco, Toledo, Ohio
- Pennzoil, Oil City, Pennsylvania
- Penreco, Karns City, Pennsylvania
Chemical
- Dow, Midland, Michigan
- Dow Corning, Midland, Michigan
- Oxy, Niagara Falls, New York
Sugar/Beverage
- Michigan Sugar (Caro, Bay City, Croswell, Sebewaing), Michigan
- American Crystal Sugar (Moorhead, East Grand Forks, Cookstown, Drayton)
- Labatt, Toronto, Canada
- Molson, Toronto, Canada
Automotive/Motorized/OEM’s
- Ford Motor Company – Plants and Corporate (Avon Lake Assembly, Lorain
Assembly, Van Dyke Transmission, Rouge Assembly, Kansas City Assembly,
Atlanta Assembly, Kentucky Truck, Louisville Assembly, Norfolk Assembly,
Twin Cities Assembly, Oakville Assembly, Michigan Assembly, Michigan Truck,
Cleveland Engine, Windsor Casting, Windsor Engine, Valencia – Spain,
Vietnam, India)
- General Motors – Plant and Corporate (Oshawa Assembly, Tonawanda Engine,
Lordstown Assembly, Harrison Radiator, Fort Wayne Assembly, Flint Engine,
Buick City, Shanghai General Motors - China)
- Chrysler – Plant and Corporate (Belvidere, Windsor, Sterling Heights, Toledo,
Kokomo, Curitiba - Brazil)
- Transplants – Toyota, Nissan, Honda
- Bombardier, Montreal, Canada
- CN Rail, Edmonton/Montreal, Canada
- Johnson Control, Milwaukee, Wisconsin
- Lear Corporation, Detroit, MI
- Visteon, Detroit, MI
- PPG Auto Corporate, Troy, MI/Canada
- Outboard Marine Corp (Evinrude), Waukegan, Illinois
- Bosch (ZF Lenksysteme), Hebron, Kentucky
Energy
- Entergy, Beaumont, Texas
Engineering Companies/Environmental/Specialty
- Arcadis, Malcom Pirnie, Conestoga Rovers, Shaw Group, Black and Veatch, Chester
Engineering, Butcher, Clean Harbors, Chemtron, Comprehensive, Energis, Oliver
Hatcher, Praxair, Sheppard T. Powell Associates, Rudolf/Libbe, Rust Engineering, SEI,
Skanska, Siemens, TRW, Whitman, Requardt and Associates, LLP, York, R.E. Warner,
Engineers Plus, Ghafari, CDM Smith, CH2M, HDR, Van Cleef, MWH.
Municipalities (Waste Water Treatment)
- Steubenville WWTP, Steubenville, OH
- Largo WWTP, Largo, FL
- East Bay Dischargers Association (EBDA), Oakland, CA
- Gallinas WWTP, Las Gallinas, CA
- Two Bridges WWTP, Two Bridges, NJ
- Alma WWTP, Alma, Michigan
- Crystal Lake WWTP, Crystal lake, IL
- South Bend WWTP, South Bend, IN
- Coshocton Water Plant, Coshocton, OH
- Sydney WWTP, Sydney, OH
- Mansfield WWTP, Mansfield, OH
- Lima WWTP, Lima OH
- Portsmouth WWTP, Portsmouth, OH
- Niles WWTP, Niles, OH
- Memphis WWTP, Memphis, TN (Stiles/Maxson)
- MWRD, Chicago, IL Calumet/Northside)
- Fremont WWTP, Fremont, OH
- Mendota WWTP, Mendota, OH
- Flagler Beach WWTP, Flagler Beach, FL
- Fort Smith WWTP, Fort Smith, AR
- Hannibal WWTP, Hannibal, MI
- Pierre WWTP, Pierre, SD
- Lexington WWTP, Lexington, TN
- Humboldt WWTP, Humboldt, TN
- Parkdale WWTP, Parkdale, OR
- Pontiac WWTP, Pontiac, IL
- Junction City WWTP, Junction City, OR
- Three Rivers WWTP, WA
- Tri-city WWTP, Portland, OR
- Decatur WWTP, Decatur, AL
- Warren WWTP, Warren, OH
- Hunts Point WWTP, Hunts Point NY
Municipalities (CSO’s)
- Bayonne CSO, Bayonne, NJ
- Chapatan CSO, McComb County, MI
- Hubble-Southfield CSO, Detroit, MI
- Baby Creek CSO, Detroit, MI
- Fort Madison CSO, Fort Madison, IA
- Conner Creek CSO, St. Clair Shores, MI
- New York City CSO, New York, NY
- Muddy Creek CSO, Cincinnati, OH
- St. Aubin CSO, Detroit, MI

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Technical_Career_Accomplishments-R._Freeborn

  • 1. Design/Build/Outsourcing Projects Robert Freeborn Listed below are some of the various projects from simple outsourcing of materials to full scale projects to designing, building, owning, operating and maintaining very detailed systems. 1. Ford, Lorain Assembly (1991) – Chrome Destruction process (D/B/O/M). 2. Rouge Steel/Ford (1987) – Automated Outfall Control System (D,B) 3. WCI Steel (1990-1995) – Designed cascading blowdowns (4 systems), solids handling (clarification), Chemical Storage/Handling for 5 systems for a new continuous caster. (D/B/M) 4. Republic Engineered Steel (1996) – Re-designed WWTP including new filtration system First Nalco/US Filter “TWO” project (D/B/M) 5. Republic Engineered Steel (1997) – Complete water pretreatment/Filtration system for new continuous caster. (D/B/O/M) 6. British Paperboard, England/Scotland (1999) – Developed and implemented complete Facilities Management program for Chemicals, Industrial Services and maintenance. (D/O/M) 7. Shanghai General Motors (1999) – Collaborated with PPG to provide facilities management for the new SGM plant in China (D/O/M) 8. Chrysler, Curitiba, Brazil (2000) – Designed water pretreatment, storage, filtrations systems for a new assembly plant in Brazil with PPG. (D/M) 9. GM, Tonawanda (2001) – Collaborated with York and Praxair for a new chiller/cooling system for the Tonawanda Engine plant (D/B/O/M) 10. IPSCO, Montpelier, Iowa (2001) – Proposed full takeover of the utility systems (river water clarification, pretreatment, filtration and discharge) for a mini-mill. (Operate and Maintain) 11. Bethlehem Steel, Sparrows Point (2000) – Collaborated with Infilco Degremond to re-design the final discharge system (Humphrey’s creek) for the entire steel mill. (D/B/O/O/M) 12. American Crystal Sugar, Fargo, ND (2001) – Developed and implemented a facilities management program for chemicals, industrial services and operations of chemical systems for the sugar industry (Design/Operate/Maintain) 13. Ford Motor Company (2001-2008) – Facilities Manger (Tier 1)
  • 2. Bio/Technical Achievements Robert Freeborn Listed below are some of my achievements in troubleshooting and solving technical issues with utility systems, audit facilities to prepare O&M recommendations, and be part of teams to correct operational issues be it mechanical of chemical in nature. I have strong knowledge of water system from municipal to middle market and even heavy industrial settings, using creative methods (both mechanical and chemical) to overcome obstacles in industrial environments. These are not all the technical situations that have been encountered in industrial applications but give a flavor of the variety of problems I have encountered and some “out of the box” thinking required to solve these problems. Steel 1. WCI Steel – Warren, Ohio (1993-1996) - Was the lead water consultant for the installation of a single slab, continuous caster. The utility support system included five separate and distinct water systems for: Makeup Water, Mold water (100,000 gal. system), Machine Water (250,000 gallons), Spray Water (350,000 gallons) and Vacuum Degasser water (100,000 gallons). Our creative Amiad strained makeup water took solids down to 10 microns in size allowing for direct use as makeup for the systems. Mold water was softened to prevent scaling in the molds, machine water was conditioned to cool bearings, rolls and heat exchange equipment, spray water was treated for Hydroflouric acid generation and system wide corrosion, and the vacuum degasser water treated for solids and scale inhibition. Process Consulting - The biggest success was designing in cascading blowdown’s for one system to another with compatible chemistries to render only 100 gallons per minute blowdown, discharged from the facility. Normal caster systems would be anywhere from 500-1000 gallons per minute. Designed in, up-front cost savings. - A challenge rose when mold powders changed, causing high hydrofluoric acid generation in the spray water. To prevent iron hydroxide from forming with the addition of caustic, a stoicimetric procedure was developed to add sodium bicarbonate (baking soda) as the alkalinity replacement, stabilizing levels, preventing system wide corrosion and eliminating the precipitation of iron hydroxide. Problem Solved - The mold powder also had a secondary impact on the machine operation. This was and is a widespread problem that continues in continuous casters. Calcium fluoride formed as a result of temperature and evaporation causing hoses to break, material buildup and loss of heat transfer. A simple and inexpensive chemical application stopped the deposition immediately. Problem Solved
  • 3. 2. Republic Engineered Steel – Canton, Ohio (1994-1995) - Spearheaded the first outsourcing project between US Filter and Nalco to design, build, and operate a new water treatment facility fitting into the existing footprint. The existing system could not handle the oil and grease or solids loading and a filtration process was developed to meet all discharge permits. - Consulted on a new water facility for a 4 strand bar caster working directly with the engineering firm in Italy to meet water quality requirements for and EMS system and high quality mold water. Process Consulting 3. IPSCO Steel – Davenport, Iowa (2000-2001) - Led project team to determine scope and operating plan for all the water and utility systems at IPSCO Steel. This did not include the electrical distribution system. All equipment was evaluated, maintenance records reviewed, repair and replacement costs determined and improvements in the water handling process in the mill investigated to bring water quality up to standards. System involved were an electric furnace operation, continuous caster, oily water separation equipment, and hot and cold rolling mills. Of particular problems were contaminated makeup water from the Mississippi, combined rolling mill/caster spray water systems and capacity issues requiring wells. Process Consulting 4. Rouge Steel – Dearborn, MI (1984- 1990) - Provided technical support to revamp the treatment and operating conditions for the terminal treatment facility for Rouge Steel and Ford Dearborn Assembly Plant. The system produced 1000 gallons per minute through two (2) 1,000,000 gallon clarifiers and then used a 5 million gallon settling basin for secondary treatment. Compliance issues were a monthly event and were eliminated with creative rerouting of water, automation and upstream chemical applications.- Problem Solved - Serviced the Rouge powerhouse for three years improving the pretreatment system to reduce chemical costs $250,000 per year. Four 1800 lb. Boilers and three 250 lb boilers produced steam for turbo blowers, electric turbines service steam for then entire Rouge complex including Double-Eagle Steel. The boilers were coal fired, tangential gas burner retrofitted experiencing tube failures due to long term overheating. A tube preventive replacement program was initiated to prevent catastrophic failures. The combination of improved water quality, increased system monitoring and preventive tube failures, allowed the facility to operate until it’s final end in 2000. – Problems Solved, Reduced Operating Costs - Blast Furnace discharge problems with ammonia almost caused a plant shutdown. Breakpoint chlorination was used for ammonia destruction but incoming ammonia caused by high coke ammonia levels could not be addressed with current equipment. The source was identified, a team I was part of, was sent to New Boston Coke to identify the problem and recommend a fix. Evaluating the quenching process and byproducts treatment, a fix was implemented, ammonia levels came back in line and water discharge could resume. Problem Solved - Provided technical assistance in the design and construction of a new two strand continuous caster in 1986-1988. Innovative technologies, automation, material
  • 4. handling and equipment recommendations provided state of the art conditions for product quality. Working with fifteen (15) Parkson upflow filters, two 50,000 gallon clarifiers and associated heat exchange equipment, water quality remained a constant for optimal operating conditions. Designed in Cost Control - Was part of a technical team from Rouge, US Steel and Nalco to evaluate the utility problems at Double Eagle Steel Galvanizing Line in Dearborn, MI only two years after startup. Changes in piping, steam requirements, equalization and treatment systems allowed the plant to meet zinc discharge limits continuously below 0.07 ppm. Problem Solved 5. US Steel - Great Lakes Works [Great Lakes, National] (1982 to present) - Provided water consulting for the installation of the #2 caster and vacuum degasser in 1988. Process Consulting - Participated in a task force to troubleshoot the water systems in 1996. Severe oil fouling, filter failure and lost production prompted focus on changing piping and control systems. Process Consulting - Presented an outsourcing project for replacement of the disk filters at the Zug Island, blast furnace recycle system with centrifuges. This project would be from design, to build, own and maintain the facility. Failures in “asset management” companies such as Enron, postponed decisions to outsource and drove the process internally. Process Consulting/Outsourcing - Assumed technical responsibility for the #2 caster water systems in November 2008. Technical problems associated with severe structural corrosion (over 15 years) attributed to Hydrogen Fluoride form mold powders and numerous bearing failures (over 10 years) prompted immediate investigation. Online corrosion monitoring with system chemistry determine the cause of the corrosion (alkalinity depression system wide) and recommendations were made to adjust system chemistry to prevent further system wide impact. Bearing failure analysis of deposits in the bearings led to external causes and procedures for cleaning and external contamination were immediately put into practice. Problems Solved in less than one month.
  • 5. Refining 1. Marathon, Detroit - Identified heat exchanger failure form analyzing condensate for organics. Once sample hit ambient air, the organic would flash off dropping condensate pH almost to a pH of 4.0. To prevent flashing and false pH impact, cooled condensate was passed through an analex cartridge, sealed and the resin was tested for organics. The result was the presence of hexadecane, cyclopentane and other friedl crafts breakdown products of benzene, toluene and xylene determining the failed heat exchanger. Problem Solved 2. Pennzoil, Pennsylvania - Isolated the foulant on filter media causing pretreatment fouling and system shutdown. Complete pretreatment fouling was caused by the many oxidations states of manganese and proper chemical treatment before the filters remedied the problem. Problem Solved 3. Marathon, Detroit - Feedwater line corrosion after the deaerator feeding high pressure steam generators for the crude unit indicated leaks in the feedwater line. Detailed oxygen testing concluded deaerator failure itself prompting a premature crude unit shutdown and subsequent prevention of catastrophic failure in the unit. Problem Solved
  • 6. Pulp and Paper 1. British Paperboard (London, England and Aberdeen, Scotland) – Personally identified the cause for loss of the biofilm on an effluent treatment system four weeks after the event occurred. Plant personnel and water experts were baffled but investigation of plant logs, maintenance records and inspection of equipment led to the conclusion that several failed bearings generated particulate metallic copper in enough quantities to “poison” the film. The film was cleaned without analysis, the bearings replaced and film was reestablished without determination of cause. Problem Solved 2. Stone Container, Coshocton, OH – 1800 pound boiler feedwater capacity problems were determined to be result of short runs with the demineralizers caused by fluctuating incoming hardness, alkalinity and pH. The cause was incomplete cold lime softening by the city and steps were made to consult with the city to produce consistent water quality for the paper mill and prevent “red” water throughout the city of Coshocton. (municipal) Problem Solved 3. Tenneco, Red Bluff, CA (Egg carton plant) – During a chemical review and plant walk-through to evaluate a chemical management program, a mechanical recommendation was made to spray calcium stearate only on egg cartons passing through the production stream. The micro- switch recommendation saved the customer over $20,000 per year in calcium stearate loss. Problem Solved and Reduced Operating Costs
  • 7. Pharmaceutical 1. Upjohn, Kalamazoo, MI – Severe internal chiller fouling slowed the production of Minoxidil (Rogaine). Complete system surveys (flow, temperature, heat exchange, pressures) identified low flow conditions and the heat exchangers were repiped to increase cooling flow required for product production. Problem Solved and Product Quality Improvements 2. Upjohn, Kalamazoo, MI – Cyanide contaminated waste was being deep well injected and the facility wanted to investigate methods to prevent the practice. Third party expertise was arranged to treat the waste stream through mechanical and chemical means and stopped the deep well injection. Environmental
  • 8. Automotive 1. Ford, Lorain Assembly (1991) – Designed, constructed and installed a point source, “chrome destruction” process for the pretreatment line. Typical waste water volumes of over 500,000 gallons per day were typical to reduce hexavalent chrome to the trivalent form in existing water treatment design. The “point source treatment” system was designed, built and installed according to my specifications utilizing two pH control systems and automatic chemical treatment (sodium bisulfite) for 50 gpm of concentrated chrome solution. This assured that the chrome was reduced resulting in dramatic operational cost reductions for acid and caustic typically used to drop pH below 4.0 and then raise the 500,000 gallons up for solids precipitation and discharge. Improved Process, Reduced Operating Costs 1. Ford Corporate – Participated in corporate monthly meetings (with Betz, Nalco and Drew) in the early 90’s as part of the Total Fluids program to standardize all water treatment parameters, limits, acceptable products and performance criteria for assembly and powertrain facilities. Process Consulting 2. Ford, Avon Lake Assembly – Identified a “Weak Link” in the weld water system allowing particulate iron to foul welder tips. Mechanical changes and operational changes were recommended to prevent the problem from reoccurring saving loss of tips, downtime, and improvement in product quality. Problem Solved and Reduced Operating Costs 3. Ford, Van Dyke Transmission (Elimination of a Hazardous Waste) - A waste stream containing lead (lead dust from machining) was disposed through a hazardous material handling company prior to review. Discussing the waste with metals recovery suppliers, the waste was able to be rerouted and turn it into a raw material. Environmental 4. Ford, Van Dyke Transmission - “Best Practice” awarded in 2006 for Trash to Energy. Facility received 2 environmental awards in 2007 for landfill avoidance. 2007-2008 landfill avoidance - 81% with only 4 waste streams left to achieve 100%. Environmental activities key for Michigan Corporate Citizenship award for 2007 and Ford Environmental awards for 2006. Environmental 5. Ford, Van Dyke Transmission - The waste water treatment plant operations and cost were scrutinized to reduce or even eliminate the dependence on the facility. Water flows were dramatically reduced due to new machining and plant downsizing. Potential operating savings of $500,000 per year were targeted. Ford corporate delegated further investigation but has been tabled due to reduced internal resources. Process Consulting
  • 9. 6. Ford, Ohio Assembly Plant – Waste from van production was estimated at a tare weight of 80 #/unit for new Econoline line. Offsite sequencing using my data reduced tare to 61 #/unit in 6 months. Continued mapping through 2006 -2007 further reduced tare to 55 #/unit. Waste minimization initiatives further reduced tare to 50.64 #/unit. Total tare reduction in 2 years – 36.25% Environmental/Cost Reduction 7. GM, Lordstown, Assembly – Determined the cause of compressor failures due to scale formation in the heat exchangers. The use of a carbamate based biocide, with controlled feed formed calcium carbamate. Changeover to the proper biocide, control of conductivity and blowdown remedied the problem. Problem Solved - Process Improvement 8. GM, Lordstown, Assembly – “White rust” problems with aluminum heat exchangers with non-treated water prompted online evaluation of products to treat multi-metal system. Proper control, chemical treatment and blowdown remedied the problem. Problem Solved 9. GM, Lordstown, Assembly – RO fouling for “ELPO” makeup and subsequent replacement of the RO membranes drove investigation into the proper chemical and mechanical changes to pretreatment before the RO’s. The system needed to be redesigned and fit into the existing space to provide for filtration and dechlorination prior to RO treatment. Problem Solved 10. GM, Lordstown, Assembly - Paint stack failures necessitated the investigation of corrosive water on stack joints. A sampling station was erected and stack tests were conducted to determine the corrositivity of the water. It was determined that the cause was two fold. The first, booth balance and the second, stack metallurgy. The stacks were designed to be stainless but cost concerns settled on mild steel without joint protection causing the failure at the stack joints. Process Consulting - Problem Solved 11. Ford, Valencia, Spain – Review of the waste treatment plant identified problems with proper application of chemical treatment for a continuous process. 95% of Fords’ plants are designed as batch processed while Valencia used the same treatment chemicals and application technology causing high variability and upset conditions. Mechanical and chemical changes were recommended and plant upsets were eliminated. Process Consulting
  • 10. 12. GM, Lordstown Assembly – Post precipitation problems existed with the discharge filters due to over addition of lime in the precipitation process for pretreatment wastes. New pH guidelines, alternative chemical recommendations and improved testing eliminated the problem and cost to re-bed the filters. Process Consulting 13. Ford, Lorain Assembly (Boiler Failures) – Ford had shut down the on-site boilers and opted for Clayton Steam generators. The steam generators (6) took plant condensate and makeup to provide necessary process steam. After six months, three boilers experienced catastrophic failures due to high condensate iron levels. Ford legal and the tier 1 total fluids manager blamed the water treatment company but deep dives into operating records, water sampling, operating recommendations and design criteria indicated poor system design and subsequently Ford accepting responsibility. Process Consulting 14. Ford, Lorain Assembly – The city of Lorain cited Ford for discharging untreated waste directly into the municipal system. Upon investigation and chemical demonstrations, the precipitation of pretreatment waste was from an operator discharging a 250,000 gallon batch without treatment and subsequent precipitation of materials in the municipal plant overloading the facility. Ford legal accepted fault for the untreated discharge based on pH logs and test demonstrations. Process Consulting
  • 11. Industries, Corporations, Facilities and Systems Listed below are the corporations and facilities that I have called on, serviced or managed throughout my career. It is not complete though indicates the various industries and applications I have encountered. Some of the facilities may now be renamed, bought out by other entities or even torn down. Steel International (Mini and Integrated) - AHMSA Steel, Mexico - Sidor Steel, Venezuela - Hamburg Steel Works, Germany - Badische Steel Works, Germany - Klockner Works, Germany - Thyssen-Krupp, Germany - British Steel, England (Teeside, Sheffield, Scunthorpe) - Allied Steel, Cardiff Wales - Fiat, Belo Horizonte, Brazil - Firth Brown, Sheffield, England - Avesta Steel, Sweden - Fagersta Steel, Sweden - Creusot Loire Steel, France (2 mills) - Voest Alpine, Austria - Bolzano Steel, Italy - Beltrame Steel, Italy - Usinor, Belgium/France - New Holland Italia, Italy - Magneti Marelli, Italy - Caffaro, Italy Domestic (Mini and Integrated, Aluminum, Specialty) - US Steel (Baytown, Gary, Great Lakes, ET, Fairless Works, Lorain and corporate) - Bethlehem Steel (LA, Seattle, Burns Harbor, Sparrows Point) - LTV Steel (Cleveland, Chicago and corporate) - AK Steel (Middletown, Ashland) - Armco Steel (Butler, Kansas City, Houston, Mansfield) - North Star Steel (Minn./St. Paul, Wilton, Monroe) - WCI Steel, Warren, Ohio - Republic Engineered Steel, Canton, OH
  • 12. - Interlake Steel, Wilder, Kentucky - LaClede Steel, Alton, Illinois - Lukens Steel, Coatesville, PA - Green River Steel, Owensboro, Kentucky - Birmingham Steel, Birmingham, Alabama - MacSteel, Jackson, Michigan - Georgetown Steel, Beaumont, Texas - Nucor Steel, Norfolk, Nebraska - Newpoot, Steel, Newport, Kentucky - Raritan Steel, Raritan, New Jersey - Chaparral Steel, Midlothian, Texas - Ipsco Steel, Muscatine, Iowa - J&L Specialty, Detroit, Michigan - Washington Steel, Massillon, Ohio - Rouge/Severstal, Dearborn, Michigan - Timkin, Canton, Ohio - Special Metals, Canton, Ohio - Brush Wellman (Copper/Beryllium), Elmore, Ohio - Alcoa (Cleveland, Newburgh, Massena and corporate) - Double Eagle Steel (Galvanizer), Dearborn, Michigan Pulp and Paper - Stone Container, Ohio - Port Huron Paper, Michigan - Crown Vantage Paper, Michigan - Tenneco Packaging, Red Bluff, California - Weyerhaeuser, Washington - Grief Brother’s, Ohio - Willamette, Beaverton, Oregon - PCA, Rittman, Ohio - Weyerhaeuser, Minneapolis/St. Paul Refining - Marathon, Detroit, Michigan - BP, Toledo, Ohio (and corporate) - Sunoco, Toledo, Ohio - Pennzoil, Oil City, Pennsylvania - Penreco, Karns City, Pennsylvania
  • 13. Chemical - Dow, Midland, Michigan - Dow Corning, Midland, Michigan - Oxy, Niagara Falls, New York Sugar/Beverage - Michigan Sugar (Caro, Bay City, Croswell, Sebewaing), Michigan - American Crystal Sugar (Moorhead, East Grand Forks, Cookstown, Drayton) - Labatt, Toronto, Canada - Molson, Toronto, Canada Automotive/Motorized/OEM’s - Ford Motor Company – Plants and Corporate (Avon Lake Assembly, Lorain Assembly, Van Dyke Transmission, Rouge Assembly, Kansas City Assembly, Atlanta Assembly, Kentucky Truck, Louisville Assembly, Norfolk Assembly, Twin Cities Assembly, Oakville Assembly, Michigan Assembly, Michigan Truck, Cleveland Engine, Windsor Casting, Windsor Engine, Valencia – Spain, Vietnam, India) - General Motors – Plant and Corporate (Oshawa Assembly, Tonawanda Engine, Lordstown Assembly, Harrison Radiator, Fort Wayne Assembly, Flint Engine, Buick City, Shanghai General Motors - China) - Chrysler – Plant and Corporate (Belvidere, Windsor, Sterling Heights, Toledo, Kokomo, Curitiba - Brazil) - Transplants – Toyota, Nissan, Honda - Bombardier, Montreal, Canada - CN Rail, Edmonton/Montreal, Canada - Johnson Control, Milwaukee, Wisconsin - Lear Corporation, Detroit, MI - Visteon, Detroit, MI - PPG Auto Corporate, Troy, MI/Canada - Outboard Marine Corp (Evinrude), Waukegan, Illinois - Bosch (ZF Lenksysteme), Hebron, Kentucky Energy - Entergy, Beaumont, Texas
  • 14. Engineering Companies/Environmental/Specialty - Arcadis, Malcom Pirnie, Conestoga Rovers, Shaw Group, Black and Veatch, Chester Engineering, Butcher, Clean Harbors, Chemtron, Comprehensive, Energis, Oliver Hatcher, Praxair, Sheppard T. Powell Associates, Rudolf/Libbe, Rust Engineering, SEI, Skanska, Siemens, TRW, Whitman, Requardt and Associates, LLP, York, R.E. Warner, Engineers Plus, Ghafari, CDM Smith, CH2M, HDR, Van Cleef, MWH. Municipalities (Waste Water Treatment) - Steubenville WWTP, Steubenville, OH - Largo WWTP, Largo, FL - East Bay Dischargers Association (EBDA), Oakland, CA - Gallinas WWTP, Las Gallinas, CA - Two Bridges WWTP, Two Bridges, NJ - Alma WWTP, Alma, Michigan - Crystal Lake WWTP, Crystal lake, IL - South Bend WWTP, South Bend, IN - Coshocton Water Plant, Coshocton, OH - Sydney WWTP, Sydney, OH - Mansfield WWTP, Mansfield, OH - Lima WWTP, Lima OH - Portsmouth WWTP, Portsmouth, OH - Niles WWTP, Niles, OH - Memphis WWTP, Memphis, TN (Stiles/Maxson) - MWRD, Chicago, IL Calumet/Northside) - Fremont WWTP, Fremont, OH - Mendota WWTP, Mendota, OH - Flagler Beach WWTP, Flagler Beach, FL - Fort Smith WWTP, Fort Smith, AR - Hannibal WWTP, Hannibal, MI - Pierre WWTP, Pierre, SD - Lexington WWTP, Lexington, TN - Humboldt WWTP, Humboldt, TN - Parkdale WWTP, Parkdale, OR - Pontiac WWTP, Pontiac, IL - Junction City WWTP, Junction City, OR - Three Rivers WWTP, WA - Tri-city WWTP, Portland, OR - Decatur WWTP, Decatur, AL - Warren WWTP, Warren, OH - Hunts Point WWTP, Hunts Point NY
  • 15. Municipalities (CSO’s) - Bayonne CSO, Bayonne, NJ - Chapatan CSO, McComb County, MI - Hubble-Southfield CSO, Detroit, MI - Baby Creek CSO, Detroit, MI - Fort Madison CSO, Fort Madison, IA - Conner Creek CSO, St. Clair Shores, MI - New York City CSO, New York, NY - Muddy Creek CSO, Cincinnati, OH - St. Aubin CSO, Detroit, MI