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KUMANA & ASSOCIATES
Consulting Engineers – Process Optimization
email jkumana@aol.com
3642 Robinson Road 180 rue de Florimont
Missouri City, Texas 77459 Mont St-Hilaire, Québec J3H 4C5
USA Canada
Phone +1-281-437-5906 Phone +1-450-446-5229
____________________________________________________________________________________
K&A specializes in the field of Value Enhancing Practices (e.g., pinch analysis) for process
improvement - energy conservation, wastewater minimization, capacity debottlenecking. We
also offer process/CHP modeling and analysis services, management consulting for corporate
Energy Management programs, training courses, and market studies. We have a proven track
record of reducing energy costs by 15-40% for major manufacturing companies, in the U.S. as
well as internationally in Europe, Middle East, Asia, Africa, and Latin America.
The Company is organized as a network of independent consultants and Alliance Part-
ners who are recognized experts in their respective fields. Each associate is responsible for
maintaining his own private practice, but involves others from the network preferentially to
join him in the execution of selected projects.
CAPABILITIES & SERVICE PORTFOLIO
• Process heat recovery optimization, using Pinch Analysis, fouling mitigation, HX mods, etc
• Electrical power conservation and recovery – load mgmt, ASDs
• Simulation modeling/optimization of Combined Heat & Power (cogeneration) systems
• Water conservation and Wastewater minimization, using Pinch Analysis
• Process + Utilities Performance Indices (KPI development and on-line implementation)
• Seminars/courses in Process Integration techniques for energy/waste reduction
• Process Engg, including heat & material balances, P&IDs, equipt specs, project mgmt, etc
• Technical Management consulting (energy strategy, technology transfer, R&D support, market
studies & support, due diligence, expert witness, forensic audits, etc)
• International work experience in N & S America, Middle-east, Europe, Asia, and Africa.
Key Associates* and Alliance Partners - Areas of Expertise
Jimmy D. Kumana, MS, ChE Energy/water optim’n, CHP modeling, EM programs
Gert-Jan Fien, MS ChE Process modeling/optimization – oil and gas
Y. R. Mehra, BS, ChE Process design and technology - gas processing
Harry R. Cripps, MSc, ChE Process Integration for pulp & paper, food/bev proc
Peter S. Hallas, BSc, ChE Process Integration for food & beverage industry
Paul C Tripathi, MS ChE Process Integration – energy, water; Energy Mgmt
Manuel R. Suarez, BS, ChE VFD applications specialist
Jacques Desroches, BS, ChE Engineering design – pulp/paper and food/bev
Sarosh Manekshaw, MS, ChE Environmental compliance
Dr. Meherwan P. Boyce, PhD, ME Gas Turbine expert, author of GT Handbook
Graphet Inc Data Mining & visualization, statistical analysis
Hudson Technologies Refrigeration systems
Furnace Improvements Inc Fired heaters - troubleshooting & optimization
Soteica Ideas & Technology LLC CHP system optimization software + implementation
* All Associates have a minimum of 20 yrs experience in their fields of expertise.
Kumana & Associates Page 2 of 9
INDUSTRIAL EXPERIENCE
• hydrocarbon industry (oil and gas production, oil refining, gas processing)
• petrochemicals, inorganics, and specialty chemicals
• pulp & paper
• food & beverage (grain processing, ethanol, sugar refining, breweries, dairy, fruit/veg processing)
• electric utilities
• government agencies and trade/industry organizations
Mr. Kumana holds a masters degree in chem eng from the Univ
of Cincinnati, and has more than 35 years of experience in
process design and energy/water optimization, working for both
manufacturing and engineering design companies before
establishing K&A in 1997, specializing in Process Integration
(Pinch Analysis). He has been a consultant to major corporations
world-wide including Shell, Amoco (BP), Dupont, Monsanto
(Solutia), Union Carbide (Dow), Enron, Saudi Aramco, SABIC,
Mitsubishi Heavy Industries, and SASOL, as well as to US Dept of
Energy, Natural Resources Canada, World Bank and UNIDO. He
has authored or co-authored over 75 technical papers and book
chapters, and currently teaches a 4-day public course (twice a
year, in Houston, Tx) on energy optimization in the oil, gas and
petrochemical industry.
Professional History
1997-pres Founder and CEO, Kumana & Associates, Houston, TX
2002-2007 Energy Consultant, Saudi Aramco, Dhahran, Saudi Arabia
1986-1997 Principal Consultant, Linnhoff March Inc, Houston, TX
1984-1986 Founder and Managing Director, Kumana & Boyce, Pensacola, FL
1979-1984 Chief Process Engineer, Henningson Durham & Richardson Inc, Pensacola, FL
1972-1979 Process Engineer, Raphael Katzen Associates, Cincinnati, OH
Summary
• 35+ years experience in process engineering/design and technical/business consulting -
focused on cost reduction through improving manufacturing efficiency and pollution
prevention. Typical savings in range of 15-40% of baseline costs.
• Broad knowledge – oil & gas, chemicals, pulp/paper, food/beverage, and electric utilities.
• International experience – N & S America, Europe, Middle East, Asia, Africa.
• Specialize in creative solutions to difficult problems, with focus on energy/water optimization.
• Member AIChE. Instructor for course #263 on Process Integration (Pinch Analysis).
Education and Professional Affiliations
M.S., Chemical Engineering, University of Cincinnati, Ohio, USA
B.S., Chemical Engineering, Indian Institute of Technology, Bombay, India
Continuing Ed – completed all courses and exam towards Ph.D. (abd), 6 MBA courses.
Mr. Kumana is a full member of the American Institute of Chemical Engineers and φλυ honor
society, and has held PE licenses in Ohio, Florida, Louisiana, and Nebraska.
Kumana & Associates Page 3 of 9
Highlights of Project Experience – Oil, Gas & Petrochemicals
Client Plant Description Scope of Work
American Cyanamid
(Cytec), Milton, Fl
Acrylic polymer and fibers
plant
Optimum HEN retrofit for energy savings,
using pinch analysis
Apache Corp
Monument, NM, USA
170-well 2500 bpd oil-field
production lease
Identify cost-effective electric power
savings potential (24%)
Arco Chemical (now BP),
Channelview, Tx
Beta phenyl ethanol plant Detailed process engineering, based on
licensed Sumitomo process
Commercial Alcohols, Ltd
Varennes, Quebec
60,000 gpd synthetic
ethanol plant
Reactor debottlenecking and design of
ether/aldehyde distillation system.
Conoco/Pennzoil JV
Westake, La, USA
New lube oil plant at 240
MBD refinery
Optimization of 32 MBD Hydrocracking
and 20 MBD Catalytic dewaxing units
ConocoPhillips Maljamar,
NM, USA
300-well 1600 bpd oil-field
production lease
Identify cost-effective electric power
savings potential (23%)
Devon Energy
Oklahoma City, Ok, USA
150-well oil-field lease in
southeastern New Mexico
Identify cost-effective electric power
savings potential (20%)
DCP Midstream (Duke
ConocoPhillips), Linam
Ranch, NM, USA
170 MMscfd “midstream”
gas processing plant
Identify cost-effective elec power savings
potential (13%); more with cogeneration
DuPont, Wilmington, De Kevlar process Pinch analysis of refrigeration system
Essar Oil Ltd,
Vadinar, Gujarat, India
300 MBD oil refinery Analysis of crude oil fouling in the CDU
preheat train
Lubrizol Corp
Deer Park, Tx
Polyisobutylene plants (2) Electric power minimization for
refrigreration and cooling water systems
Monsanto (Solutia),
Decatur, Al
Acrylic fibers and nylon
intermediates
Water conservation to debottleneck WWT
capacity, using pinch analysis
Monsanto (Solutia),
Sauget, Il
12-unit complex producing
chlorinated C6H6 compds
(a) Total site energy pinch study
(b) Total site water pinch study
Monsanto (Solutia),
Chocolate Bayou, Tx
Acrylonitrile plant Refrig system and cooling tower
debottlenecking study (pinch analysis)
Monsanto (Solutia),
7 N American sites
Misc specialty chemicals
mfr, batch and continuous
“Opportunity Assessment” studies to
identify scope for cost reduction
Mitsubishi Heavy Indus,
Tokyo, Japan
Styrene monomer synthesis
& refining
Optimization of new HEN and distillation
sequence, using pinch analysis
Navajo Refining Co (Holly
corp), USA
100 MBD refinery in New
Mexico
Preliminary assessment of energy saving
potential via CHP optimization
Occidental Petroleum
Los Angeles, Ca, USA
80-well 1200 bpd oil-field
lease in New Mexico
Identify cost-effective electric power
savings potential (25%)
Olin Chemicals,
Lake Charles, La
TDA/TDI complex, incl
phosgene & HyCO
Optimum HEN retrofit for energy savings,
using pinch analysis
Pemex, Mexico Oil refining & Petrochem Training courses on Energy Optimization
PetroChina, Karamayi,
XinJiang, China
200 MBD lube oil refinery
revamp + expansion
Optimum HEN retrofit for 6 units + 5 new
units + Site Utilities (energy+water)
Petrowax,
Smethport, Pa, USA
Petroleum wax extraction
and refining plant
Optimum HEN retrofit for energy savings
and NOx emissions reduction
Quaker Chemical Co,
Belle Glade, Fl
Tetra-hydrofuran from
furfural
Techno-economic feasibility study
Refineria Isla (PdVSA),
Curacao
200 MBD oil refinery 5-day training course in process
integration using Pinch Analysis
SABIC,
Jubail, Saudi Arabia
2 MeOH plants + 1 MTBE
plant (Ibn Sina + Ibn Zahr)
Energy audit and optimization of heat
recovery and CHP systems
Kumana & Associates Page 4 of 9
Oil, Gas & PetroChem project experience, continued
Sasol Chemical
Industries, Sasolburg,
South Africa
Coal gasification and
chemicals complex
(a) Water conservation and wastewater
minimization study, (b) Energy
optimization study; using pinch analysis
Sasol Chemical
Industries, Secunda,
South Africa
Coal gasification and
chemicals complex
Water conservation and wastewater
minimization study; using pinch analysis
Saudi Aramco, corp
engg, Dhahran, Saudi
Arabia
Oil stabilization, oil refining,
and gas processing plants
Quick Energy audits (6 major sites),
including gas processing and oil refning
Saudi Aramco, Shedgum
Gas Plant, Saudi Arabia
2200 MMscfd gas
processing plant, incl NGL
rec
Detailed energy optimization study – total
site, incl CHP model
Saudi Aramco, Juaymah
Gas Plant, Saudi Arabia
NGL condensate
fractionation
Optimum HEN retrofit design, ASDs,
Energy Performance Indices
Saudi Aramco, Yanbu
Refinery, Saudi Arabia
230 MBD fuels refinery Detailed energy optimization study – total
site, incl CHP model
Saudi Aramco, Hawiyah,
Saudi Arabia
1600 MMscfd gas plant, incl
NGL recovery
Conceptual energy optimization study –
total site, incl CHP model
Saudi Aramco, Safaniya,
Saudi Arabia
2400 MBD crude oil GOSP
+ desalting + dehydration
facility
Detailed energy optimization study – total
site, incl utilities (cogen)
Saudi Aramco, Jeddah,
Saudi Arabia
85 MBD fuels refinery Mgmt of detailed energy optimization study
outsourced to EPC contractor
Saudi Aramco, Rabigh,
Saudi Arabia
400 MBD fuels refinery Development+application of optimum load
mgmt strategies for pump networks
Saudi Aramco, Ras
Tanura, Saudi Arabia
300 + 225 MBD fuels
refineries
Mgmt of detailed energy optimization study
outsourced to EPC contractor
Saudi Aramco, Riyadh,
Saudi Arabia
120 MBD fuels refinery Detailed energy optimization study of H2
prod + HCU + CHP model + cogen
strategy
Saudi Aramco, Manifa
CPF, Saudi Arabia
900 MBD crude oil GOSP +
desalt + dehydration facility
Energy-optimized design of new plant,
including utilities (cogen)
Saudi Aramco, corporate
engineering, Dhahran,
Saudi Arabia
Oil & gas production, oil
refining and gas processing
• Developed + taught multiple energy
optimization courses (>100 students)
• Developed and deployed Energy
Performance Indices
• Prepared five Best Practice manuals
related to energy efficiency
• Revised corporate standards and
procedures to include energy efficiency
Southern Union Gas, Jal,
NM, USA
90 MM scfd gas processing
plant
Identified cost-effective elec savings
potential (10%) + cogeneration (65%)
Tesoro, Los Angeles,
California, USA
360 MBD fuels refinery Capacity debottlenecking of Delayed
Coking Unit via HEN retrofit (20%)
Tex-Penn Inc,
Houston, Tx, USA
Waste lube oil reclamation
plant
Process development, detailed process
design
Tosco (now Tesoro),
Avon/Martinez, Ca, USA
156 MBD oil refinery Total site energy study using pinch
analysis
XTO Energy
Eunice, NM, USA
170-well 2500 bpd oil-field
production lease
Identify cost-effective electric power
savings potential (15%)
Kumana & Associates Page 5 of 9
Highlights of Project Experience – Water Conservation & WW Minimization
Client Plant Description Scope of Work
Monsanto (Solutia),
Decatur, Alabama
Acrylic fibers and nylon
intermediates
Water conservation to debottleneck
WWT capacity, using pinch analysis
Monsanto (Solutia),
Sauget, Illinois
12-unit complex
producing chlorinated
C6H6 compds
(c) Total site energy pinch study
(d) Total site water pinch study
Monsanto (Solutia),
Chocolate Bayou, Tx
Acrylonitrile plant Refrig system and cooling tower
debottlenecking study (pinch analysis)
Sasol Chemical
Industries, Sasolburg,
South Africa
Coal gasification and
chemicals complex
(a) Water conservation and wastewater
minimization study, and (b) Total site
energy optimization study; using pinch
analysis
Sasol Chemical
Industries, Secunda,
South Africa
Coal gasification and
chemicals complex
Water conservation and wastewater
minimization study; using pinch analysis
Jefferson Smurfit,
Monroe, Michigan
110 TPD linerboard mill Energy savings, water conservation and
wastewater minimization
Mead Westvaco Corp,
Escanaba, Michigan
1650 TPD bleached Kraft
pulp/paper mill
Combined thermal and water
conservation retrofit study, using Pinch
Analysis
Mead Westvaco Corp,
Chillicothe, Ohio
950 TPD bleached Kraft
pulp/paper mill
Combined thermal and water
conservation retrofit study, using Pinch
Analysis
Rayonier Inc,
Jesup, Georgia
1700 TPD bleached Kraft
pulp/paper mill (3 lines)
Combined thermal and water
conservation retrofit design, using Pinch
Analysis
Tyson Foods,
Cumming, Georgia
20,000 birds/h poultry
processing facility
Simulation model, retrofit for WWT
capacity debottlenecking via water
conservation
Elec Power Res
Institute, Palo Alto,
California
Customer Tech
Assistance program
Preparation of publication on “Water
Conservation using Pinch Technology”
Kumana & Associates Page 6 of 9
Highlights of Project Experience – Gas and Electric Utilities
Client Program Scope of Work
Elec Power Res Institute,
Palo Alto, Ca
Customer Technical
Assistance
Technical support to marketing depts at
various member utilities
Elec Power Res Institute,
Palo Alto, Ca
R&D New methodology for joint HEN/CHP
optimization
Elec Power Res Institute,
Palo Alto, Ca
Customer Tech Assistance Preparation of publication on “Water
Conservation using Pinch Technology”
Detroit Edison
Detroit, Mi
Customer Technical
Assistance
Energy optimization studies for an oil
refinery and a paper mill
Dubai Supply Authority
Dubai, UAE
Global Opex reduction via
integrated optimization of
T&D system with Strategic
Storage facility
(a) Compressor Re-Configuration study
for Emergency conditions
(b) Optimize operating policy and
practices for normal operation
Enbridge Consumers Gas,
Toronto, Canada
Marketing Customized spreadsheet model of CHP
system, for use by account managers
Gas Research Insttute
Chicaogo, IL
Customer Technical
Assistance
Energy efficiency study of frozen citrus
juice plant
Gulf Power Co
Pensacola, Fl
Customer Technical
Assistance
Energy optimization study for pulp mill
Enron Energy
Houston Texas
Identifying ESCO
opportunities
Determine energy cost saving
opportunities in support of ESCO program
– glass and paper industries
Minnesota Power Co
Duluth, Mn
Customer Technical
Assistance
Energy optimization study for pulp and
paper mill
Oklahoma Gas & Elec,
Oklahoma City, Ok
Customer Technical
Assistance
CHP simulation and evaluation of drive
options for a university
Pennsylvania Elec Co,
Bradford, Pa
Customer Technical
Assistance
Energy optimization study for a wax
extraction and refining plant
Public Service E&G of NJ,
Newark, NJ
Customer Technical
Assistance
Capacity debottlenecking studies for two
specialty chemical plants
Southern California Gas
Los Angeles, Ca
Process Gas Cooling –
market assessment study
Applications of GAX equipment in printing,
plastics, and dry-cleaning businesses
Southern Company,
Birmingham, AL
Customer Technical
Assistance
Energy pinch study for a pulp/paper mill;
water balance for poultry plant
Southern California
Edison, Rosemead, Ca
Customer Technical
Assistance
Energy optimization and capacity
debottlenecking studies for 7 plants -
refinery, brewery, gypsum wallboard plant,
2 paper mills, 2 glass plants
Utah Power & Light,
Salt Lake City, Ut
Customer Technical
Assistance
Energy cost reduction studies for 3 plants
– (2 potato processing, 1 metals)
Xcel Energy
St Paul, Mn
Technical support for
Industrial DSM Program
Energy efficiency consulting for 18
industrial customers in Minnesota and
New Mexico
Xcel Energy
Denver, Co
Technical support for
Industrial DSM Program
Evaluation of variable voltage controllers
for electric motors
Kumana & Associates Page 7 of 9
Highlights of Project Experience – Government, Commercial, & Institutions
Client Program Scope of Work
Amer Inst of Chem Engr,
New York, NY
Scheduled continuing
education courses (3-day)
Instructor for course on Process
Integration using Pinch Analysis, 6 years
Government of Egypt,
Ministry of Petroleum and
Minerals
Energy Efficiency Training
Program for the Oil, Gas,
and Petrochem sector
Develop and teach a suite of technical
and energy management courses
throughout the year (ongoing)
Government of Saudi
Arabia
National Energy Efficiency
Program
Advise on national energy strategy in
collaboration with JICA (Japan
International Cooperation Agency).
Resulted in mandatory cogeneration of
electric power and desalinated seawater
Intl. Finance Corp (World
Bank Group), Wash DC
Cleaner Production
program in Latin America
& Caribbean
Site visits to IFC client sites – Cement,
Lime, Food, Paper – as part of due
diligence on energy/water conservation
projects
Institute for Industrial
Productivity, Wash DC
Energy Systems
Optimization standards
Advisory services to CNIS for Chinese
oil refining industry
Institute for International
Education, Wash DC
Training in industrial
energy efficiency
improvement
Teach 5 day course in Process
Integration as part of a 6-week intensive
program
Natural Resources
Canada
Varennes, Quebec
CANMET energy program Miscellaneous consulting on industrial
energy sector profiles, and program
strategy
State of Texas,
Austin, Tx
Sustainable Economic
Development Council
Study of energy savings potential in
Texas industry + public testimony
US Dept of Energy,
Office of Industrial
Technologies
Steam Challenge Advisory Committee member; technical
input on publications and “best practice”
tools
US Dept of Energy,
Washington, DC
Steam Best Practices Preparation of Fact Sheet for calculating
steam costs
US Agency for Intl Dev,
Washington, DC
PACER program for India,
in collaboration with ICICI
Project mgmt of R&D effort, training
seminars, publicity, and promotion
US Agency for Intl Dev,
Washington, DC
Aid to Mexico 1-day Energy Efficiency course in
Mexico city
US Naval Civil Eng Lab,
Pt Hueneme, Ca
Energy cost reduction at
NARFs and shipyards
Evaluation of energy savings potential at
on-shore naval military facilities
Winnebago Indian Tribe,
Winnebago, Ne
Economic development
program
Feasibility study for fuel-ethanol plant
Kumana & Associates Page 8 of 9
Selected Publications
1. J D Kumana, “Medium Scale Alcohol Technology and Economics”, presented at the Annual
Technical Meeting, National Gasohol Commission, Minneapolis, Mn (July 21, 1980).
2. R Katzen, G D Moon and J D Kumana, “Distillation System for Motor Fuel Grade
Anhydrous Alcohol”, U.S. Patent 4,217,178 (Aug 12, 1980).
3. J D Kumana and S P Kothari, “Predict Storage Tank Heat Transfer Precisely”, Chemical
Engineering, Vol 89 (Mar 22, 1982), pp 127-132.
4. J D Kumana, “A Review of DDGS Drying Technology”, presented at the Second
Ethanol/Methanol Conference, Hamilton, Bermuda (Apr 24-26, 1983).
5. J D Kumana, “A Pre-Design Strategy for Selecting Near-Optimum Cooling Water Flow
Rates”, AIChE Symposium Series no. 236, Vol 80, (1984), pp 117-121.
6. J D Kumana, “Ethanol from Molasses - A Technology Update”, All-India Distillers
Association Conference, New Delhi, India (March 5-6, 1986).
7. J D Kumana, “How to Increase Revenues from Ethanol and By-Products”, presented at the
Gist-Brocades Ethanol Production Workshop, Kansas City, Mo (June 9-10, 1986).
8. D M Jenkins and J D Kumana, “Pinch Technology Applications in Sugar Processing”, Proc.
of SIT Annual Technical Meeting, Sydney, Australia (May 11-13, 1987).
9. J D Kumana, “Control Valve Sizing Under Variable Flow Conditions Using an Electronic
Spreadsheet”, Chemical Processing magazine, Vol 53, no. 8 (June 1990).
10. J D Kumana, “The Impact of Excess Boiling Point Rise in Evaporators and Crystallizers”,
Chem Eng Prog, Vol 86, no 5 (May 1990), p 10.
11. J D Kumana, “Run Batch Distillation Process with Spreadsheet Software”, Chem Eng Prog,
Vol 86, no 12 (Dec 1990), p 53.
12. R Nath, J D Kumana and J F Holliday, “Optimum Dispatching of Plant Utility Systems to
Minimize Cost and Local NOx Emissions”, Proc of ASME Indus Power Conf, New Orleans,
La (Mar 1992).
13. J D Kumana et al, chapters 4, 18, and 23 in “Waste Minimization Through Process Design”,
McGraw-Hill, New York, NY (1995).
14. R J Doherty and J D Kumana, “A Step-by-Step Approach to Energy Conservation”,
Chemical Processing (Jan 1996), p 90.
15. B Linnhoff, R A Tainsh and J D Kumana, “Intelligent Networking of Process Wastewater
Streams in the Chemical Industry”, GVC conference Verfahrenstechnik der Abwasser und
Schlammbehand-lung, Wurzburg, Germany (Oct 1996).
16. J D Kumana, “Integrated Water Management - A Systematic Approach”, presented at
AIChE’s CWRT workshop, St Louis, Mo (Nov 10, 1999).
17. J D Kumana, “Use Spreadsheet-based CHP Models to Identify and Evaluate Energy Cost
Reduction Opportunities in Industrial Plants”, Proc of 23rd
Industrial Energy Technology
Conference, Houston, Texas (May 2001).
18. J D Kumana, “A Stochastic Approach to Calculating Return on Investment”, Proc of First
International Symposium on Exergy, Energy and Environment, Izmir, Turkey (July 13-17,
2003).
19. J D Kumana, “Pinch Analysis: A Practical Tool for Effective Water Management”, Proc of
Petrotech 2003 Conference, Bahrain (Sep 29 – Oct 1, 2003).
20. J D Kumana and Ahmed S Aseeri, “Electrical Power Savings In Pump And Compressor
Networks Via Load Management”, Proc of 27th
Industrial Energy Technology Conference,
New Orleans, La (May 2005).
Kumana & Associates Page 9 of 9
21. J D Kumana , “Success Factors for a Corporate Energy Program”, presentation at 29th
Industrial Energy Technology Conference, New Orleans, La (May 9-10, 2007).
22. J D Kumana, “Meaningful Energy Efficiency Performance Metrics for the Process
Industries”, Proc of 31st
Industrial Energy Technology Conference, New Orleans, La (May
12-15, 2009).
23. J D Kumana, “Using Corporate Standards and Procedures to Promote a Sustainable
Energy Program”, presented at the Texas Chemical Council Annual EHS Conference,
Galveston, Texas (June 10, 2010)
24. J D Kumana, “Corporate Energy Management Programs: A Case Study”, Chemical News
(India), (Nov 2010).
25. J D Kumana, “Analysis Tools for Integrated Process Optimization: Energy, Emissions, and
Throughput”, presented at AEE’s 33rd World Energy Engineering Congress, Washington,
DC (Dec 8-10, 2010).
26. J D Kumana, “Effective Fouling Control Methods for Improving CDU Performance and
Economics”, International Petroleum Refining (Jan 2012) pp 21-31

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Kumana & Assoc - Quals (O&G + P-chem) 1-15

  • 1. KUMANA & ASSOCIATES Consulting Engineers – Process Optimization email jkumana@aol.com 3642 Robinson Road 180 rue de Florimont Missouri City, Texas 77459 Mont St-Hilaire, Québec J3H 4C5 USA Canada Phone +1-281-437-5906 Phone +1-450-446-5229 ____________________________________________________________________________________ K&A specializes in the field of Value Enhancing Practices (e.g., pinch analysis) for process improvement - energy conservation, wastewater minimization, capacity debottlenecking. We also offer process/CHP modeling and analysis services, management consulting for corporate Energy Management programs, training courses, and market studies. We have a proven track record of reducing energy costs by 15-40% for major manufacturing companies, in the U.S. as well as internationally in Europe, Middle East, Asia, Africa, and Latin America. The Company is organized as a network of independent consultants and Alliance Part- ners who are recognized experts in their respective fields. Each associate is responsible for maintaining his own private practice, but involves others from the network preferentially to join him in the execution of selected projects. CAPABILITIES & SERVICE PORTFOLIO • Process heat recovery optimization, using Pinch Analysis, fouling mitigation, HX mods, etc • Electrical power conservation and recovery – load mgmt, ASDs • Simulation modeling/optimization of Combined Heat & Power (cogeneration) systems • Water conservation and Wastewater minimization, using Pinch Analysis • Process + Utilities Performance Indices (KPI development and on-line implementation) • Seminars/courses in Process Integration techniques for energy/waste reduction • Process Engg, including heat & material balances, P&IDs, equipt specs, project mgmt, etc • Technical Management consulting (energy strategy, technology transfer, R&D support, market studies & support, due diligence, expert witness, forensic audits, etc) • International work experience in N & S America, Middle-east, Europe, Asia, and Africa. Key Associates* and Alliance Partners - Areas of Expertise Jimmy D. Kumana, MS, ChE Energy/water optim’n, CHP modeling, EM programs Gert-Jan Fien, MS ChE Process modeling/optimization – oil and gas Y. R. Mehra, BS, ChE Process design and technology - gas processing Harry R. Cripps, MSc, ChE Process Integration for pulp & paper, food/bev proc Peter S. Hallas, BSc, ChE Process Integration for food & beverage industry Paul C Tripathi, MS ChE Process Integration – energy, water; Energy Mgmt Manuel R. Suarez, BS, ChE VFD applications specialist Jacques Desroches, BS, ChE Engineering design – pulp/paper and food/bev Sarosh Manekshaw, MS, ChE Environmental compliance Dr. Meherwan P. Boyce, PhD, ME Gas Turbine expert, author of GT Handbook Graphet Inc Data Mining & visualization, statistical analysis Hudson Technologies Refrigeration systems Furnace Improvements Inc Fired heaters - troubleshooting & optimization Soteica Ideas & Technology LLC CHP system optimization software + implementation * All Associates have a minimum of 20 yrs experience in their fields of expertise.
  • 2. Kumana & Associates Page 2 of 9 INDUSTRIAL EXPERIENCE • hydrocarbon industry (oil and gas production, oil refining, gas processing) • petrochemicals, inorganics, and specialty chemicals • pulp & paper • food & beverage (grain processing, ethanol, sugar refining, breweries, dairy, fruit/veg processing) • electric utilities • government agencies and trade/industry organizations Mr. Kumana holds a masters degree in chem eng from the Univ of Cincinnati, and has more than 35 years of experience in process design and energy/water optimization, working for both manufacturing and engineering design companies before establishing K&A in 1997, specializing in Process Integration (Pinch Analysis). He has been a consultant to major corporations world-wide including Shell, Amoco (BP), Dupont, Monsanto (Solutia), Union Carbide (Dow), Enron, Saudi Aramco, SABIC, Mitsubishi Heavy Industries, and SASOL, as well as to US Dept of Energy, Natural Resources Canada, World Bank and UNIDO. He has authored or co-authored over 75 technical papers and book chapters, and currently teaches a 4-day public course (twice a year, in Houston, Tx) on energy optimization in the oil, gas and petrochemical industry. Professional History 1997-pres Founder and CEO, Kumana & Associates, Houston, TX 2002-2007 Energy Consultant, Saudi Aramco, Dhahran, Saudi Arabia 1986-1997 Principal Consultant, Linnhoff March Inc, Houston, TX 1984-1986 Founder and Managing Director, Kumana & Boyce, Pensacola, FL 1979-1984 Chief Process Engineer, Henningson Durham & Richardson Inc, Pensacola, FL 1972-1979 Process Engineer, Raphael Katzen Associates, Cincinnati, OH Summary • 35+ years experience in process engineering/design and technical/business consulting - focused on cost reduction through improving manufacturing efficiency and pollution prevention. Typical savings in range of 15-40% of baseline costs. • Broad knowledge – oil & gas, chemicals, pulp/paper, food/beverage, and electric utilities. • International experience – N & S America, Europe, Middle East, Asia, Africa. • Specialize in creative solutions to difficult problems, with focus on energy/water optimization. • Member AIChE. Instructor for course #263 on Process Integration (Pinch Analysis). Education and Professional Affiliations M.S., Chemical Engineering, University of Cincinnati, Ohio, USA B.S., Chemical Engineering, Indian Institute of Technology, Bombay, India Continuing Ed – completed all courses and exam towards Ph.D. (abd), 6 MBA courses. Mr. Kumana is a full member of the American Institute of Chemical Engineers and φλυ honor society, and has held PE licenses in Ohio, Florida, Louisiana, and Nebraska.
  • 3. Kumana & Associates Page 3 of 9 Highlights of Project Experience – Oil, Gas & Petrochemicals Client Plant Description Scope of Work American Cyanamid (Cytec), Milton, Fl Acrylic polymer and fibers plant Optimum HEN retrofit for energy savings, using pinch analysis Apache Corp Monument, NM, USA 170-well 2500 bpd oil-field production lease Identify cost-effective electric power savings potential (24%) Arco Chemical (now BP), Channelview, Tx Beta phenyl ethanol plant Detailed process engineering, based on licensed Sumitomo process Commercial Alcohols, Ltd Varennes, Quebec 60,000 gpd synthetic ethanol plant Reactor debottlenecking and design of ether/aldehyde distillation system. Conoco/Pennzoil JV Westake, La, USA New lube oil plant at 240 MBD refinery Optimization of 32 MBD Hydrocracking and 20 MBD Catalytic dewaxing units ConocoPhillips Maljamar, NM, USA 300-well 1600 bpd oil-field production lease Identify cost-effective electric power savings potential (23%) Devon Energy Oklahoma City, Ok, USA 150-well oil-field lease in southeastern New Mexico Identify cost-effective electric power savings potential (20%) DCP Midstream (Duke ConocoPhillips), Linam Ranch, NM, USA 170 MMscfd “midstream” gas processing plant Identify cost-effective elec power savings potential (13%); more with cogeneration DuPont, Wilmington, De Kevlar process Pinch analysis of refrigeration system Essar Oil Ltd, Vadinar, Gujarat, India 300 MBD oil refinery Analysis of crude oil fouling in the CDU preheat train Lubrizol Corp Deer Park, Tx Polyisobutylene plants (2) Electric power minimization for refrigreration and cooling water systems Monsanto (Solutia), Decatur, Al Acrylic fibers and nylon intermediates Water conservation to debottleneck WWT capacity, using pinch analysis Monsanto (Solutia), Sauget, Il 12-unit complex producing chlorinated C6H6 compds (a) Total site energy pinch study (b) Total site water pinch study Monsanto (Solutia), Chocolate Bayou, Tx Acrylonitrile plant Refrig system and cooling tower debottlenecking study (pinch analysis) Monsanto (Solutia), 7 N American sites Misc specialty chemicals mfr, batch and continuous “Opportunity Assessment” studies to identify scope for cost reduction Mitsubishi Heavy Indus, Tokyo, Japan Styrene monomer synthesis & refining Optimization of new HEN and distillation sequence, using pinch analysis Navajo Refining Co (Holly corp), USA 100 MBD refinery in New Mexico Preliminary assessment of energy saving potential via CHP optimization Occidental Petroleum Los Angeles, Ca, USA 80-well 1200 bpd oil-field lease in New Mexico Identify cost-effective electric power savings potential (25%) Olin Chemicals, Lake Charles, La TDA/TDI complex, incl phosgene & HyCO Optimum HEN retrofit for energy savings, using pinch analysis Pemex, Mexico Oil refining & Petrochem Training courses on Energy Optimization PetroChina, Karamayi, XinJiang, China 200 MBD lube oil refinery revamp + expansion Optimum HEN retrofit for 6 units + 5 new units + Site Utilities (energy+water) Petrowax, Smethport, Pa, USA Petroleum wax extraction and refining plant Optimum HEN retrofit for energy savings and NOx emissions reduction Quaker Chemical Co, Belle Glade, Fl Tetra-hydrofuran from furfural Techno-economic feasibility study Refineria Isla (PdVSA), Curacao 200 MBD oil refinery 5-day training course in process integration using Pinch Analysis SABIC, Jubail, Saudi Arabia 2 MeOH plants + 1 MTBE plant (Ibn Sina + Ibn Zahr) Energy audit and optimization of heat recovery and CHP systems
  • 4. Kumana & Associates Page 4 of 9 Oil, Gas & PetroChem project experience, continued Sasol Chemical Industries, Sasolburg, South Africa Coal gasification and chemicals complex (a) Water conservation and wastewater minimization study, (b) Energy optimization study; using pinch analysis Sasol Chemical Industries, Secunda, South Africa Coal gasification and chemicals complex Water conservation and wastewater minimization study; using pinch analysis Saudi Aramco, corp engg, Dhahran, Saudi Arabia Oil stabilization, oil refining, and gas processing plants Quick Energy audits (6 major sites), including gas processing and oil refning Saudi Aramco, Shedgum Gas Plant, Saudi Arabia 2200 MMscfd gas processing plant, incl NGL rec Detailed energy optimization study – total site, incl CHP model Saudi Aramco, Juaymah Gas Plant, Saudi Arabia NGL condensate fractionation Optimum HEN retrofit design, ASDs, Energy Performance Indices Saudi Aramco, Yanbu Refinery, Saudi Arabia 230 MBD fuels refinery Detailed energy optimization study – total site, incl CHP model Saudi Aramco, Hawiyah, Saudi Arabia 1600 MMscfd gas plant, incl NGL recovery Conceptual energy optimization study – total site, incl CHP model Saudi Aramco, Safaniya, Saudi Arabia 2400 MBD crude oil GOSP + desalting + dehydration facility Detailed energy optimization study – total site, incl utilities (cogen) Saudi Aramco, Jeddah, Saudi Arabia 85 MBD fuels refinery Mgmt of detailed energy optimization study outsourced to EPC contractor Saudi Aramco, Rabigh, Saudi Arabia 400 MBD fuels refinery Development+application of optimum load mgmt strategies for pump networks Saudi Aramco, Ras Tanura, Saudi Arabia 300 + 225 MBD fuels refineries Mgmt of detailed energy optimization study outsourced to EPC contractor Saudi Aramco, Riyadh, Saudi Arabia 120 MBD fuels refinery Detailed energy optimization study of H2 prod + HCU + CHP model + cogen strategy Saudi Aramco, Manifa CPF, Saudi Arabia 900 MBD crude oil GOSP + desalt + dehydration facility Energy-optimized design of new plant, including utilities (cogen) Saudi Aramco, corporate engineering, Dhahran, Saudi Arabia Oil & gas production, oil refining and gas processing • Developed + taught multiple energy optimization courses (>100 students) • Developed and deployed Energy Performance Indices • Prepared five Best Practice manuals related to energy efficiency • Revised corporate standards and procedures to include energy efficiency Southern Union Gas, Jal, NM, USA 90 MM scfd gas processing plant Identified cost-effective elec savings potential (10%) + cogeneration (65%) Tesoro, Los Angeles, California, USA 360 MBD fuels refinery Capacity debottlenecking of Delayed Coking Unit via HEN retrofit (20%) Tex-Penn Inc, Houston, Tx, USA Waste lube oil reclamation plant Process development, detailed process design Tosco (now Tesoro), Avon/Martinez, Ca, USA 156 MBD oil refinery Total site energy study using pinch analysis XTO Energy Eunice, NM, USA 170-well 2500 bpd oil-field production lease Identify cost-effective electric power savings potential (15%)
  • 5. Kumana & Associates Page 5 of 9 Highlights of Project Experience – Water Conservation & WW Minimization Client Plant Description Scope of Work Monsanto (Solutia), Decatur, Alabama Acrylic fibers and nylon intermediates Water conservation to debottleneck WWT capacity, using pinch analysis Monsanto (Solutia), Sauget, Illinois 12-unit complex producing chlorinated C6H6 compds (c) Total site energy pinch study (d) Total site water pinch study Monsanto (Solutia), Chocolate Bayou, Tx Acrylonitrile plant Refrig system and cooling tower debottlenecking study (pinch analysis) Sasol Chemical Industries, Sasolburg, South Africa Coal gasification and chemicals complex (a) Water conservation and wastewater minimization study, and (b) Total site energy optimization study; using pinch analysis Sasol Chemical Industries, Secunda, South Africa Coal gasification and chemicals complex Water conservation and wastewater minimization study; using pinch analysis Jefferson Smurfit, Monroe, Michigan 110 TPD linerboard mill Energy savings, water conservation and wastewater minimization Mead Westvaco Corp, Escanaba, Michigan 1650 TPD bleached Kraft pulp/paper mill Combined thermal and water conservation retrofit study, using Pinch Analysis Mead Westvaco Corp, Chillicothe, Ohio 950 TPD bleached Kraft pulp/paper mill Combined thermal and water conservation retrofit study, using Pinch Analysis Rayonier Inc, Jesup, Georgia 1700 TPD bleached Kraft pulp/paper mill (3 lines) Combined thermal and water conservation retrofit design, using Pinch Analysis Tyson Foods, Cumming, Georgia 20,000 birds/h poultry processing facility Simulation model, retrofit for WWT capacity debottlenecking via water conservation Elec Power Res Institute, Palo Alto, California Customer Tech Assistance program Preparation of publication on “Water Conservation using Pinch Technology”
  • 6. Kumana & Associates Page 6 of 9 Highlights of Project Experience – Gas and Electric Utilities Client Program Scope of Work Elec Power Res Institute, Palo Alto, Ca Customer Technical Assistance Technical support to marketing depts at various member utilities Elec Power Res Institute, Palo Alto, Ca R&D New methodology for joint HEN/CHP optimization Elec Power Res Institute, Palo Alto, Ca Customer Tech Assistance Preparation of publication on “Water Conservation using Pinch Technology” Detroit Edison Detroit, Mi Customer Technical Assistance Energy optimization studies for an oil refinery and a paper mill Dubai Supply Authority Dubai, UAE Global Opex reduction via integrated optimization of T&D system with Strategic Storage facility (a) Compressor Re-Configuration study for Emergency conditions (b) Optimize operating policy and practices for normal operation Enbridge Consumers Gas, Toronto, Canada Marketing Customized spreadsheet model of CHP system, for use by account managers Gas Research Insttute Chicaogo, IL Customer Technical Assistance Energy efficiency study of frozen citrus juice plant Gulf Power Co Pensacola, Fl Customer Technical Assistance Energy optimization study for pulp mill Enron Energy Houston Texas Identifying ESCO opportunities Determine energy cost saving opportunities in support of ESCO program – glass and paper industries Minnesota Power Co Duluth, Mn Customer Technical Assistance Energy optimization study for pulp and paper mill Oklahoma Gas & Elec, Oklahoma City, Ok Customer Technical Assistance CHP simulation and evaluation of drive options for a university Pennsylvania Elec Co, Bradford, Pa Customer Technical Assistance Energy optimization study for a wax extraction and refining plant Public Service E&G of NJ, Newark, NJ Customer Technical Assistance Capacity debottlenecking studies for two specialty chemical plants Southern California Gas Los Angeles, Ca Process Gas Cooling – market assessment study Applications of GAX equipment in printing, plastics, and dry-cleaning businesses Southern Company, Birmingham, AL Customer Technical Assistance Energy pinch study for a pulp/paper mill; water balance for poultry plant Southern California Edison, Rosemead, Ca Customer Technical Assistance Energy optimization and capacity debottlenecking studies for 7 plants - refinery, brewery, gypsum wallboard plant, 2 paper mills, 2 glass plants Utah Power & Light, Salt Lake City, Ut Customer Technical Assistance Energy cost reduction studies for 3 plants – (2 potato processing, 1 metals) Xcel Energy St Paul, Mn Technical support for Industrial DSM Program Energy efficiency consulting for 18 industrial customers in Minnesota and New Mexico Xcel Energy Denver, Co Technical support for Industrial DSM Program Evaluation of variable voltage controllers for electric motors
  • 7. Kumana & Associates Page 7 of 9 Highlights of Project Experience – Government, Commercial, & Institutions Client Program Scope of Work Amer Inst of Chem Engr, New York, NY Scheduled continuing education courses (3-day) Instructor for course on Process Integration using Pinch Analysis, 6 years Government of Egypt, Ministry of Petroleum and Minerals Energy Efficiency Training Program for the Oil, Gas, and Petrochem sector Develop and teach a suite of technical and energy management courses throughout the year (ongoing) Government of Saudi Arabia National Energy Efficiency Program Advise on national energy strategy in collaboration with JICA (Japan International Cooperation Agency). Resulted in mandatory cogeneration of electric power and desalinated seawater Intl. Finance Corp (World Bank Group), Wash DC Cleaner Production program in Latin America & Caribbean Site visits to IFC client sites – Cement, Lime, Food, Paper – as part of due diligence on energy/water conservation projects Institute for Industrial Productivity, Wash DC Energy Systems Optimization standards Advisory services to CNIS for Chinese oil refining industry Institute for International Education, Wash DC Training in industrial energy efficiency improvement Teach 5 day course in Process Integration as part of a 6-week intensive program Natural Resources Canada Varennes, Quebec CANMET energy program Miscellaneous consulting on industrial energy sector profiles, and program strategy State of Texas, Austin, Tx Sustainable Economic Development Council Study of energy savings potential in Texas industry + public testimony US Dept of Energy, Office of Industrial Technologies Steam Challenge Advisory Committee member; technical input on publications and “best practice” tools US Dept of Energy, Washington, DC Steam Best Practices Preparation of Fact Sheet for calculating steam costs US Agency for Intl Dev, Washington, DC PACER program for India, in collaboration with ICICI Project mgmt of R&D effort, training seminars, publicity, and promotion US Agency for Intl Dev, Washington, DC Aid to Mexico 1-day Energy Efficiency course in Mexico city US Naval Civil Eng Lab, Pt Hueneme, Ca Energy cost reduction at NARFs and shipyards Evaluation of energy savings potential at on-shore naval military facilities Winnebago Indian Tribe, Winnebago, Ne Economic development program Feasibility study for fuel-ethanol plant
  • 8. Kumana & Associates Page 8 of 9 Selected Publications 1. J D Kumana, “Medium Scale Alcohol Technology and Economics”, presented at the Annual Technical Meeting, National Gasohol Commission, Minneapolis, Mn (July 21, 1980). 2. R Katzen, G D Moon and J D Kumana, “Distillation System for Motor Fuel Grade Anhydrous Alcohol”, U.S. Patent 4,217,178 (Aug 12, 1980). 3. J D Kumana and S P Kothari, “Predict Storage Tank Heat Transfer Precisely”, Chemical Engineering, Vol 89 (Mar 22, 1982), pp 127-132. 4. J D Kumana, “A Review of DDGS Drying Technology”, presented at the Second Ethanol/Methanol Conference, Hamilton, Bermuda (Apr 24-26, 1983). 5. J D Kumana, “A Pre-Design Strategy for Selecting Near-Optimum Cooling Water Flow Rates”, AIChE Symposium Series no. 236, Vol 80, (1984), pp 117-121. 6. J D Kumana, “Ethanol from Molasses - A Technology Update”, All-India Distillers Association Conference, New Delhi, India (March 5-6, 1986). 7. J D Kumana, “How to Increase Revenues from Ethanol and By-Products”, presented at the Gist-Brocades Ethanol Production Workshop, Kansas City, Mo (June 9-10, 1986). 8. D M Jenkins and J D Kumana, “Pinch Technology Applications in Sugar Processing”, Proc. of SIT Annual Technical Meeting, Sydney, Australia (May 11-13, 1987). 9. J D Kumana, “Control Valve Sizing Under Variable Flow Conditions Using an Electronic Spreadsheet”, Chemical Processing magazine, Vol 53, no. 8 (June 1990). 10. J D Kumana, “The Impact of Excess Boiling Point Rise in Evaporators and Crystallizers”, Chem Eng Prog, Vol 86, no 5 (May 1990), p 10. 11. J D Kumana, “Run Batch Distillation Process with Spreadsheet Software”, Chem Eng Prog, Vol 86, no 12 (Dec 1990), p 53. 12. R Nath, J D Kumana and J F Holliday, “Optimum Dispatching of Plant Utility Systems to Minimize Cost and Local NOx Emissions”, Proc of ASME Indus Power Conf, New Orleans, La (Mar 1992). 13. J D Kumana et al, chapters 4, 18, and 23 in “Waste Minimization Through Process Design”, McGraw-Hill, New York, NY (1995). 14. R J Doherty and J D Kumana, “A Step-by-Step Approach to Energy Conservation”, Chemical Processing (Jan 1996), p 90. 15. B Linnhoff, R A Tainsh and J D Kumana, “Intelligent Networking of Process Wastewater Streams in the Chemical Industry”, GVC conference Verfahrenstechnik der Abwasser und Schlammbehand-lung, Wurzburg, Germany (Oct 1996). 16. J D Kumana, “Integrated Water Management - A Systematic Approach”, presented at AIChE’s CWRT workshop, St Louis, Mo (Nov 10, 1999). 17. J D Kumana, “Use Spreadsheet-based CHP Models to Identify and Evaluate Energy Cost Reduction Opportunities in Industrial Plants”, Proc of 23rd Industrial Energy Technology Conference, Houston, Texas (May 2001). 18. J D Kumana, “A Stochastic Approach to Calculating Return on Investment”, Proc of First International Symposium on Exergy, Energy and Environment, Izmir, Turkey (July 13-17, 2003). 19. J D Kumana, “Pinch Analysis: A Practical Tool for Effective Water Management”, Proc of Petrotech 2003 Conference, Bahrain (Sep 29 – Oct 1, 2003). 20. J D Kumana and Ahmed S Aseeri, “Electrical Power Savings In Pump And Compressor Networks Via Load Management”, Proc of 27th Industrial Energy Technology Conference, New Orleans, La (May 2005).
  • 9. Kumana & Associates Page 9 of 9 21. J D Kumana , “Success Factors for a Corporate Energy Program”, presentation at 29th Industrial Energy Technology Conference, New Orleans, La (May 9-10, 2007). 22. J D Kumana, “Meaningful Energy Efficiency Performance Metrics for the Process Industries”, Proc of 31st Industrial Energy Technology Conference, New Orleans, La (May 12-15, 2009). 23. J D Kumana, “Using Corporate Standards and Procedures to Promote a Sustainable Energy Program”, presented at the Texas Chemical Council Annual EHS Conference, Galveston, Texas (June 10, 2010) 24. J D Kumana, “Corporate Energy Management Programs: A Case Study”, Chemical News (India), (Nov 2010). 25. J D Kumana, “Analysis Tools for Integrated Process Optimization: Energy, Emissions, and Throughput”, presented at AEE’s 33rd World Energy Engineering Congress, Washington, DC (Dec 8-10, 2010). 26. J D Kumana, “Effective Fouling Control Methods for Improving CDU Performance and Economics”, International Petroleum Refining (Jan 2012) pp 21-31