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 Expert  727785

Expert in Engineering Cokeless Furnaces, Slurry Pipelines, Slurry Hydrocracking, Oilsand Engineering, and Tailings

Available for your Consulting and Expert Witness Needs

Washington (WA)
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness Market Research

Summary of Expertise: Listed with other top experts in: 
Expert is a specialist in the design of gas-fired furnaces for melting of metals. He received in 2017 a grant from the National Science Foundation for the design of a cokeless melting system for ferrous castings.

Expert is the author of an influential book on the engineering of slurry systems. He has close to 30 years of experience and has worked on a large number of mining as well as oil projects. He participated in the development of a slurry hydrocracking process for a major petroleum company and is listed as the inventor for the recovery of catalysts. He has also participated in projects in Canada for the extraction of tar sands, also called oil sands. He has engineering a number of slurry pipelines for construction of tailings dam as well as long distance concentrate transportation. He has a number of publications on smelting lances, lake de-silting and froth pumping. In the last two years expert has lead the effort to get an air permit for the first commercial cokeless foundry for iron melting in the United States.

Expert has also devoted a portion of his career to catalyst recovery through his work on slurry hydrocracking. He is the principal inventor of a patent A PROCESS FOR RECOVERING ULTRAFINE SOLIDS FROM A HYDROCARBON LIQUID. Preparation of packages for purchase of fixed and rotating equipment for refinery expansion and revamp to ASME and API codes. Corrosion engineering for various units of a refinery.

Examples - Shell refinery in Anacortes, Washington - Sinclair refinery, Wyoming - Chevron Richmond refinery, California - Irving Oil refinery, New Brunswick, Canada - BP Arco, Blaine, Washington Splitvane Engineers Foundry Directed air permit application and construction for first commercial cokeless natural gas fired foundry for melting iron in the United States.

Expert has conducted research and published a paper on extracting gas hydrates from deep ocean and transporting in a slurry form.


energy-efficient gas burner


slurry fluid flow




slurry hydrotransportation


metal foundry process


oil refinery equipment


ASME boiler and pressure vessel code


pressure vessel code

Show Secondary and Basic Areas of Expertise
Expert may consult nationally and internationally, and is also local to the following cities: Seattle, Washington;  Bellevue, Washington;  Everett, Washington;  Federal Way, Washington;  Kent, Washington;  Bellingham, Washington;  and Renton, Washington.

Often requested
with this expert:

Pump Design and Applications
Oil and Gas Well Management, Operations, Production,...
Drilling Fluids
Design of Pumps, Design of Fluid Systems, System Operation,...

Year   Degree   Subject   Institution   Honors
1986   Master of Science   Materials Engineering   American University in Cairo  
1984   Diplome (Equivalent to Masters)   Economic Development Studies   Institut Universitaire d'Etudes de Developpement, Universite de Geneve  
1980   Bachelor of Science (Engineering)   Aeronautical Engineering   Queen Mary College, University of London, United Kingdom   Second Class

Work History:
Years   Employer   Department   Title   Responsibilities

2015 to


Expert's Firm




Principal Investigator


Consulting on the construction of the first cokeless foundry in the USA for melting iron and steel. Received a grant from National Science Foundation.

Confidential expert witness for failure of a phosphate pipeline.

Consulting to an oilsand extraction firm for disposal of mature fine tailings.

Fixed and rotating equipment engineer - Revamp of an oil refinery for a confidential client in Wyoming.

2013 to 2014


Expert's Firm



Technical Director


Technical Director for the York Polyhalite Pipeline - UK Conducted research on moving gas hydrates in a slurry form Subject Matter Expert for a number of peer reviews for tailings and concentrate pipelines.

2007 to 2013




Metals & Mining


Principal Design Engineer


Managed engineering of tailings pipelines for Barrick Pascua Lama, Barrick Goldstrike, Baja Mining El Boleo, Rio Tinto Kennecott, Rio Tinto Eagle Mining, PetroCanada Fort Hills.

2004 to 2007




Energy Technology


Technical Adviser


Research for the development of a slurry hydrocracking process.

2003 to 2004


SNC Lavalin and COLT Engineering (now Worley Parson)



Field Project Engineer


Field Support for the start-up of the Albian Sands Energy plant in Ft McMurray - a 155,000 barrels per day oilsand extraction plant - employed through ATS Reliance.

2001 to 2003


Anvil Corporation




Rotating Equipment and Pressure Vessel Engineer


Sizing and preparing RFQ's for pressure vessels, rotating equipment for local refineries.

2000 to 2001


Hatch Engineering, Canada and Rescan Engineering


Consultant Engineer




Contract work to Hatch & Associates, Rescan Environmental, Kilborn - design of slurry and tailings systems for mining.

1996 to 2000


Fluor Canada



Senior Mechanical Engineer


Engineering of Southern Peru Cuajone expansion, Gibraltar SX-EW plant - Lead Rotating Engineer Irving Oil Expansion - Engineering of Muskeg River Oil Sands Extraction Plant.

Career Accomplishments:

Professional Engineer, Registered in States of Washington and California, USA, and Alberta,Canada


Expert's business received a grant from the National Science Foundation for the development of a new process for melting iron in foundries using natural gas, leading to important reduction of emissions

Publications and Patents Summary

20 papers published, 4 patents including one held by Chevron for slurry hydrocracking. Author of a slurry systems handbook.

Patents include: - An internal combustion engine featuring the use of an oscillating liquid column and a hydraulic turbine to convert the energy of fuels - Centrifugal Separation Bowl with Material Accelerator - Cokeless Reverberatory Furnace with Separate Hearth and Melting Chamber - A PROCESS FOR RECOVERING ULTRAFINE SOLIDS FROM A HYDROCARBON LIQUID

Selected Publications and Publishers  
 - McGraw-Hill 2002  
 - Tailings & Mine Waste Proceedings – Vancouver, Canada 2011  
 - National Water Research Center of Egypt  
 - ASCE -Critical Transitions in Water and Environmental Resources Management Proceedings of World Wat  
 - Texas A&M University - 21st International Conference on Turbomachinery  
 - Undisclosed  

Government Experience:
Years   Agency   Role   Description
1980 to 1982   Undisclosed   Engineer   Military
1988 to 1990   CSIRO Australia   Scientist   He was in charge of the development of a new lance for the Sirosmelt process to smelt non-ferrous metal ores

Consulting Services:
Selected Consulting Examples:
  • A small foundry wanted to improve on the cokeless reverberatory cupola to melt iron with natural gas rather than coke but could not find an expert in the USA - since no commercial cokeless foundry was ever built. Expert was hired and led the process of design, obtaining the necessary air permit and order of construction from local authority for a 9000 tons per year plant.
  • Advisor to Chevron for the development of a new process called "slurry hydrocracking" - Advised on appropriate levels of catalyst, and methods to recycle spent catalyst. Research lead to a patent.
  • Lead engineer for the design of a tailings pipeline for Shell Canada/Albian Sands 150,000 barrels per day plant.
  • Engineer for Fluor - participated over 5 years to the commissioning of copper concentrators, solvent extraction plants or design of slurry systems.
  • A major gold producer had identified a site in the Andes at an altitude of 3900 m where gold was found in large quantity. However to access the ore body it was necessary to dredge a bog completely and transport water, gravel, silt and chopped up grass to a water storage pond at a higher altitude. The owner hired a geotechnical expert to conduct a feasibility study. The study initially focused on the top layers that consisted of grass, water and about 10% silt but then extrapolated to the bottom layers that contained sand and gravel up to 20 mm in diameter. The study had proposed to use 8 hydraulic excavators that were deemed very dangerous in the bog, and therefore required highly trained operators who could swim out of the bog. The 8 excavators were connected by hoses to a common pipeline to a sump on the shore feeding three pumps in series. The geotechnical consultant had assumed that the dredged material could be transported at the weight concentration of 40% while the submersible pumps typically dredged at the maximum weight concentration of 30%. ORC provided peer review but indicated that the lower layers of the bog would require more pumping power as well as operation at higher velocity than the top layers due to a much coarser particle size distribution. ORC also expressed some concern that the hydraulic excavators had experienced in some other sites accidents tipping off and leading to accidental death of an operator. The peer review recommended using an air cushion platform that exerts a minimum pressure of 1 psi to navigate the bog. This also would have allowed the use two larger hydraulic driven submersibles to reduce the number of operators, hoses to the pipeline. An air cushion dredging platform was identified in Singapore for lease as well as another one in Vancouver, British Columbia. The peer review also recommended an increase of the number of booster pumps to four in series to handle the gravel at the deepest layers. The peer reviewer also identified the risk of formation of balls of clay with chopped grass that clog the pipeline in certain points and proposed a number of solutions such as proper design of booster pump station sump, discharge approach into the storage pond. The reviewer also recommended that the reclaim pumps in the storage pond be horizontal slurry pumps rather than vertical turbine pumps.Outcome: The peer review resulted in a series of recommendations for a more stable dredging and pumping system while proposing a safer technology to avoid accidents associated with hydraulic excavators. The proposed single air cushion platform with large excavator and two large submersible pumps is also likely to reduce the number of operators and auxiliary refueling vehicles for the system proposed by the Geotechnical consultant.
  • Expert assisted a very large firm extracting oilsand in canada with very difficult disposal of mature fine tailings. Technology is currently subject to a patent application
  • Expert assisted a defendant in a 60 mile long phosphate pipeline to settle a difficult claim out of court.
  • Prepared packages for a refinery's shut down replacing heat exchangers, pressure vessels and fired heaters.
Recent Client Requests:
  • Slurry systems expert for consulting on design of system for making and pumping a slurry.
  • Slurry expert to provide an Independent Review of a slurry application.
  • Expert for consulting on Valve station by-pass Design.
  • Slurry expert firm for consulting on Slurry Distribution Plant.
  • Polymer slurry expert for consulting on Drilling with Polymer slurry.
  • Expert in Rubber Seal Issue.
  • Slurry pump expert for consulting on Slurry Pumping calculations and verification.
  • Expert for consulting on api 610 pumps.
  • Expert for consulting on Sulfosuccinate.
  • Expert for consulting on Reclamation Calssification System for oil sands.
Click the green button above to contact Expert for a free initial screening call regarding your expert consulting needs.  Expert is available for consulting to corporate, legal and government clients.  Remember, your initial screening call to speak with Expert is free.

Expert Witness:
Expert Witness Experience Summary:
Expert witness on the dredging of a hydro-electric reservoir in Colorado working for the defendant. Defendant won the case.

Expert Witness on a phosphate slurry pipeline on the side of the defendant. Defendant and Plaintiff settled out of court.

Recent Litigation Client Requests:
  • Ethanol production expert for consulting on separation of liquids from thin stillage.
Click the green button above to contact Expert for a free initial screening call regarding expert testimony, litigation consulting and support, forensic services, or any related expert witness services.  A few litigation needs include product liability, personal injury, economic loss, intellectual property (patent, trademark, trade secret, copyright), and insurance matters.  Remember, your initial screening call to speak with Expert is free.

International Experience:
Years   Country / Region   Summary
1988 to 1990   Australia   He was employed as a scientist by the CSIRO - developing smelting processes.
1990 to 1992   Australia   He worked as design engineer for Warman International, a leading manufacturer of slurry pumps.
1991 to 1995   Canada   Worked for a number of EPCMs such as ERM, Bateman Engineering, Fluor on diamonds mines, gold and copper mines including the design of a 100 km long pipeline for Chile
2004 to 2007   USA   He was hired as an Advisor to Chevron on a new process for slurry hydrocracking.
1983 to 1988   Egypt   Volunteered to Bassaisa Rural Technology center building wind mills and solar energy systems

Language Skills:
Foreign Language   Description
English   Very fluent
French   Very fluent
Arabic   Very fluent

Market Research:
He has engineered many slurry pipelines, participated recently to technical audits of two phosphate mines, mud drilling .

He has published many papers and a book.

Click the green button above to contact Expert for a free initial screening call regarding your marketing research, industry research, and company research needs.  For research needs involving multiple experts or secondary research, a Research Director can be assigned to coordinate the work into a custom report for you as a potentially quicker and more cost effective alternative to doing this work yourself or hiring a boutique consultancy.  Remember, your initial screening call to speak with Expert is free.

Additional Skills and Services:

He has taught courses in Slurry Engineering. Slurry course at the Vancouver Conference Tailings & Mine Waste

Supplier and Vendor Location and Selection

He has selected mining equipment, prepared RFQs for a number of projects in South America.

He has selected pressure vessels prepared RFQs for steam turbines, API 610 pumps for refineries

Other Skills and Services

He has led the efforts for the first cokeless foundry in the USA to melt iron and steel, has been a design engineer for a number of manufacturers of centrifugal petroleum and slurry pumps. Expert's witness won a $225K grant from the National Science Foundation in 2017 to measure emissions from this new invention.


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