1. 122 Canning Boulevard
Hopetoun, WA 6348
+61 467 073 159(mobile_personal)
+61 8 9838 3384(landline_personal)
E-mail: darrellcordeiro@hotmail.com
Darrell Ainsley Cordeiro
Personal
Information ♦ Martial Status: Married
♦ Nationality : Australian Citizen
♦ Place of Birth: Singapore
♦ Languages spoken: English, Portuguese.
Summary of
qualifications
Professional
memberships
1986 - 1989
St Johns Park High School
Sydney, New South Wales
1990
University of Western Sydney
Sydney, New South Wales
♦ Bachelor of Engineering (1st
Year)
1991 – 1995
University of New South Wales
Sydney, New South Wales
♦ Bachelor of Engineering (Chemical Engineering).
♦ Grade: 2nd
Class Honours.
2003 – 2005
Deakin University
Geelong, Victoria
♦ Graduate Certificate in Management (Business Administration).
29th
April, 2005.
♦ Institute of Chemical Engineers, Associate Membership, 20th
August,
2014.
2. Employment
Summary
First Quantum Minerals Ravensthorpe, Western Australia
February 2014 – May 2015
Process Shift Supervisor – Utilities
• Management of daily plant operations for Utilities;
• Organisation of staff training, development and performance
appraisals
• Coordination of daily operational process plant and
maintenance priorities for the Acid, Power, Water handling and
Tailings / Evaporation plant;
• Monitoring and ensuring that process plant KPI’s and targets
are adhered to on a daily basis;
• Working with maintenance and Process Engineering personnel
to ensure that Plant Process Improvement initiatives are
executed;
• Developing a safety culture within the crew to ensure that
Production targets are achieved in a safe and effective way;
• Daily reporting of Process plant parameters, targets and
maintenance priorities to both operational and management
personnel on a daily basis;
• Working with cross functional and internal operational teams to
ensure that Production bottlenecks / Process investigations are
executed in an effective and safe way.
Incitec Pivot Fertilizers Limited Phosphate Hill, North
Queensland, Australia.
January 2011 – February 2014
Senior Process Development Engineer / Assistant Process
Development Manager
Management and execution of major Capital projects in the
Phosphoric Acid / Mineral Acid production plant:
o Design, Commissioning and Implementation of a new Direct
Sulphuric Acid / Process Water washing system for the Hemi
hydrate Filtration process;
o Review and Optimisation of the washing frequency and
duration of the Weak Acid washing process for the Hemi
Hydrate Filtration / Reaction process;
o Establishment of a study into the initiation, formation and
migration of different scale species in the Phosphoric Acid
3. plant leading to the following Scale removal initiatives:
Optimisation of Plant washing procedures /
durations;
Implementation of different materials of construction
for piping / vessels to prevent scale formation /
adherence;
Implementation of new anti-scaling chemical agents
to aid in the prevention of scale formation in the
Hemi Hydrate filtration plant.
• Project return ex completion - $3 Million in additional
Phosphoric Acid production due to the following:
o More rapid turnaround in Filter plant washes;
o Reduction in equipment downtime due to more frequent /
effective Plant acid washing.
Management and execution of major Capital projects in the
Granulation / Gas-Fertiliser Production Plant:
o Design, Commissioning and Implementation of a novel process
to recycle additional Phosphoric Acid product to the Granulation
Plant – Project involves the following:
Management of external Engineering contractors
in the Design, Procurement, Installation and
Commissioning of a delivery / washing process
to recycle additional Phosphoric Acid back to the
Granulation Plant from the Gypsum waste
Evaporation ponds.
Technical Development of “Scale removal”
process to ensure robustness of the delivery
process and uptime of process equipment
utilised in the recycling process;
Technical Development, installation and
commissioning of control systems to improve
efficacy of the washing process to further
optimise equipment uptime.
o Project return to date - $4 Million in additional Fertilizer
Production from the Granulation plant due to additional
Phosphoric Acid supply to the Granulation process.
Other Management roles in the Business unit:
• Acting Process Development Engineering Manager. Duties
include:
o Supervision / Management of Projects for 2 Process
Development Engineers and 3 Senior Process
Development Engineers;
o Management of projects in the Sulphuric Acid Production
plant in Mount Isa and the Ammonia Plant located in
Phosphate Hill;
o Responsible for Recruitment and Selection of candidates
for the Process Development Department, Phosphate
4. Hill. Duties include:
Conducting site interviews;
Involved in the selection of candidates for
employment in the Department.
Process Improvement and Reliability based projects:
• Major Process Improvement projects in the Beneficiation plant
including:
o Improvements in ore washing and removal of fine
impurities in the washing circuit;
o Improvements in Hemi hydrate filter feed stock density
control by the implementation of a robust DCS Density
control system used for feed solids control;
o Improvements made in crushing efficiency by the
implementation of more effective screening media for the
removal of fine impurities in the ore feed which effect
particle settling rate.
• Major Process Reliability projects in the Ammonia Vaporisation /
Refrigeration process plant for Product Cooling:
o Investigated and reported on improvement options for
Granulated MAP/DAP Product cooling using existing
Ammonia refrigeration units in the plant;
o Investigated and reported on alternative options and pre-
feasibility studies related to the Cooling of granulated
MAP/DAP product;
o Sourced and recommended immediate, short and long
term processing options for process improvements to the
site Product Cooling facilities.
Queensland Magnesia Central Queensland, Australia.
January 2008 – December 2010
Senior Mine Process Development Engineer
Key Responsibilities
• Management of CIP for the Kunwarra Pre Concentration and
Beneficiation plant. Projects include:
o Optimisation of the Pre Concentration crushing and screening
plant for increase Yield.
o Evaluation & Optimization of Ore washing system targeting
Increase Plant Capacity and reduction in ore haulage cost.
o Evaluation & Optimisation of all current Heavy Media
Separation processes for Performance Improvement,
reduction in Heavy Media usage / losses, higher Yield and
Quality.
5. o Development & Management of Wet Chemistry laboratory
located in the Mine Site.
o Management & organization of Pilot plant test work to assess
the potential of recycling Production waste ore streams to
target Increase in existing plant Recovery.
o Management of Pilot Plant test work to assess the potential of
recovering waste ore streams to supply low grade product
markets.
Key Achievement:
• Installation of a high pressure ore washing system for the Pre-
concentration plant scalping screen to reduce / eliminate sticky
clay gangue from ore:
o Washing system was Project Managed using the FEED
process together with supplier;
o Cost of system ~ $800K, Return on investment ~ $500K
in reduction in screen downtime due to blockages.
Carter Holt Harvey, Pulp & Paper Kawerau, New
Zealand
October 2006 – January 2008
Specialist Process Engineer / Production Coordinator
Key Responsibilities
♦ Management & Organisation of Daily production schedule &
operational parameters for the Re-Causticising Plant.
♦ Management / co-ordination of Daily Planned / Un-Planned
Maintenance for the Re-Causticising Plant.
♦ Implementation & monitoring of Daily Process parameters for the
Causticising & Lime kiln plant.
♦ Coordination of Medium to Long Term Capital / Process Improvement
Projects.
♦ Management & coordination of all Area Safety & Plant Lock-out /
Access Procedures for machine shutdown / start-up.
♦ Undertake responsibilities of Deputy Area Manager in the absence of
the Area Manager.
Norske Skog Tasman Kawerau, New Zealand
August 2005 – September 2006
Process Engineer
6. Key Responsibilities
♦ Daily monitoring of Process parameters for a 400ton/day Paper
Machine.
♦ Managing and co-ordinating mid to long term Projects targeting
Paper Quality enhancement.
♦ Co-ordination & planning of New Paper product trials.
♦ Assisting & co-ordinating maintenance work for scheduled Paper
machine shut downs.
♦ Reporting on Daily & Monthly paper machine Process performance &
Wet –End Chemistry.
Alcan-Gove Pty Ltd Nhulunbuy, Northern Territory
September 2000 – July 2005
Area Production Process Engineer
Key Responsibilities
♦ Responsibilities involved the daily monitoring, review and
establishment of Secondary Operating Parameters and Key
Performance Indicator targets for the Rotary Kiln and Fluid Bed heat
Calcination plant.
♦ Heavy involvement in Continuous Improvement (both Black & Green
belt projects) projects targeted at Equipment Productivity, Process
Improvement and Sampling accuracy in the White-Side Refinery
Operations.
♦ Other Area Responsibilities include:
1) Support for Refinery Operations – Process De-Bottlenecking &
Troubleshooting.
2) Management & Supervision of Laboratory & Plant scale trials for
data gathering and Process diagnostics.
3) Management & co-ordination of several Technical and Capital
Projects in the White-side area of the Refinery.
4) Reporting on Weekly & Monthly Area Process Performance
Indicators.
5) Technical Presentations.
6) Maintenance of Metallurgical Accounting database.
Other Alumina Refinery Experiences
♦ Have also assumed Area Production Process Engineering roles for
the Hydrate Filtration / Seed Classification Plant, Precipitation
(Agglomeration / Growth) Plant and Process Monitoring roles for the
Red-side Refinery Operations (Grinding, Digestion, Mill Slurry
7. Heating, Desilication, Desanding, Security Filtration and Evaporation)
Key Achievements:
• Contributed significantly to the reduction in filtration plant filtrate
solids retention by the introduction of novel filtration cloth media
and filter modifications.
• Contributed significantly to several Research projects relating to
the continuous improvement of the Oxalate Rich filtration
process. Findings have led to the implementation of processes,
which have the potential for cost savings in the reduction of Soda
and wash water losses.
James Hardie Research Camellia, Sydney,
May 1996 – August 2000
Process Engineer
Key Responsibilities
♦ Involved in several mathematical modelling projects relating to the
improvement and control of Cellulose Fiber Reinforced Cement
manufacturing machinery and unit operations.
♦ Organization of laboratory, pilot plant and factory machine trials for
process data gathering and model validation.
♦ Involved in the design, instrumentation and procurement of pilot scale
experimental equipment for the investigation of primary process
modelling parameters in the formation of Cellulose Fiber Reinforced
Cement product from raw material sources.
♦ Management of several projects relating to the behaviour of Cellulose
Fiber Reinforced Cement slurry rheology in process machinery using
FLUENT computational fluid dynamics software package.
♦ Involved in process simulation projects targeting the increase in
Cellulose Fiber Reinforced Cement machine production throughput
and reduction in the variability of process parameters.
♦ Provide technical support to James Hardie production personnel for
process de-bottlenecking and troubleshooting.
♦ Involved in several projects relating to the development of novel low
cost product formation processes targeting thicker odd shaped
Cellulose Fiber Reinforced Cement building product profiles for
overseas markets.
♦ Other duties include generating monthly project budget reports,
providing Engineering support for the purchase and hire of new and
used equipment, providing design support for fabrication of machine
components and maintenance of project filing systems.
Key Achievements:
• 50% reduction in surface aesthetic defects in Cellulose Fiber
Reinforced Cement green product at high sheet moisture
8. Key Attributes
contents using modelling data for the design of an extended nip
point.
• 80% reduction in felt wear and power consumption per shift on
the machine due to a new design of intermediate and top vacuum
box slot width ratios provided by data from mathematical models
describing the dewatering of FRC film by suction pressure.
• Demonstrated the use of Computational Fluid Dynamic modelling
software package to James Hardie Research. Results from this
work have successfully proven the ability of CFD to model slurry
flow behaviour in James Hardie process machinery.
• Contributed to the development of a process model of a Cellulose
Fiber Reinforced Cement plant within IDEAS modelling software
package, which was utilized in training machine operators and
commissioning of equipment for James Hardie’s new factory
located in Philippines.
• Reduced the frequency of cone tank blockage and machine down
time for one of James Hardies US factories by recommending
regular cone tank underflow flush cycles. This was a result of
laboratory test work on slurry solids content and mass balance
calculations over the wet process.
Queensland Alumina Pty Ltd Gladstone, Queensland
December 1993 – February 1994
Student Process Engineer
Key Responsibilities
♦ Involved in a major project relating to the improvement of Bauxite
particle settling and precipitation in the hydro-classification area of
the plant.
♦ Other duties include performing mass balance calculations to identify
unknown process flows and laboratory test work for bauxite particle
sizing and settling.
♦ Exposure to a variety of industries, work environments and cultures
within Australia and internationally.
♦ Ability to communicate with all levels of management, project team
members and factory floor staff within an organization.
♦ Reliable individual who has the ability to drive him and others to
achieve successful results for given tasks.
♦ Meticulous in attitude and applies logic to solve difficult problems with
effective solutions without accepting initial answers as first instincts.
9. Key
Competencies
Team
Leadership
Training
♦ Competent in the use of:
1. Microsoft Word, Excel, Power point, Project and
schedule.
2. AUTOCAD LT in design drafting of machine
components for general steel fabrication.
3. Modelling software packages such as NIMBUS,
IDEAS and FLUENT Computational Fluid Dynamics.
♦ Competent in
1. Project planning and budgeting
2. Organization of value added laboratory, pilot and
production scale trials through knowledge and training
in experimental design.
3. The latest EH&S model procedures, HAZOP and Risk
Analysis studies.
• Shift Supervisor responsible for a team of 6 operations personnel,
Capital / routine plant maintenance and Production / Process targets
on a daily basis;
• Assistant Process Development Engineering Manager with Incitec
Pivot Fertilizers Limited;
• Plant Supervisor for 3 years with Norske Skog / Carter Holt Harvey
Pulp / Paper Operations;
♦ Lead a team of workshop and drafting office staff during design of
experimental scale equipment.
♦ Team organizer and leader for several pilot and production scale
trials.
♦ Deputy Chairperson of EH&S work site committee – Lead meeting
and discussion sessions for site safety committee members in
absence of chairperson.
♦ Management of laboratory personnel in Mine Site.
♦ Management of contractors and specialist Engineering consultants
for major Capital Project work.
• Received Training in lean Six Sigma (to level of Black belt).
• Received training in FLUENT Computational Fluid Dynamics from the
centre for Advanced Numerical Computation in Engineering and
Sciences (CANCES).
• Received training in the use of IDEAS process modelling software
package from Beca Simons.
• Received training in Statistical thinking, Experimental design and
Managing performance.
• Received work cover accredited training course on OH&S
(Committees in workplace) regulations, 1984. Qualified to sit on any
site safety committee.
10. Patents and
publications
References
• Received training and qualifications to authorize and issue work
clearances for Cold and Hot Work permits (accredited by SHE
Pacific).
• Received training in the Principles of Paper Making – APPITA
accredited.
• Received training and certifications in QMS (Queensland Mines
Safety Certificate) level#1 to #3;
• Competency: RIIOHS202A, Enter and Work in Confined Space,
RTO#2056 (National Licence).
• Competency: RIIOHS204A, Working Safely at heights, RTO#:2056
(National Licence).
• National Competency: Intermediate Boiler Operation, accredited by
WORKSAFE.
• National Competency: Intermediate Turbine Operation, accredited by
WORKSAFE.
• Received training in the use of MINITAB Statistical software with
proven use in Lean Six Sigma and Continuous Improvement / A3
sheet type project work.
• Received training in HAZOP / HAZID studies and have gained much
experience as a HAZOP / HAZID study leader.
• Received training in Root Cause Analysis (RCA) studies and have
gained much experience as a RCA study leader.
• Attended “Bulk Solids Handling” course units by TUNRA, University
of Newcastle.
♦ Co-writer for paper entitled:” Modelling of water removal by vacuum
suction”. Paper was presented in the 52nd
APPITA annual general
conference in 1998.
♦ Mr Jared Exton, Utilities Superintendent, First Qantum Minerals
(FQM) Australia Nickel Pty Ltd, Direct Supervisor,
Tel (mobile): +61 418 858 124.
email: jared.exton@fqml.com
• Mr Franz Schnetler, Technology Manager, MWSPC.
Tel (mobile): +966 50 474 3196
email: fschnetler@gmail.com
♦ Mr. Gerald O’Shaughnessy, Senior Process Engineer, Alcoa
(Wagerup Refinery), Tel (work): (08)9733-8481, Tel(home): (08)
9581-3290
Email: gerry.o’shaughnessy@alcoa.com.au.
♦ Mr Des O’Sulivan, Chief Process Engineer (Direct Supervisor),
ALCAN-GOVE, Tel (work): 08 8987-5554, Tel (mobile): 0418840957.
Email: des.osulivan@alcan.com.au.
♦ Mr Steve Brine, Senior Process Engineer (Direct Supervisor), Norske
Skog Tasman.
11. NB: Written work and character references are available upon request.
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