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Sean Honore

Sean Honore

Senior Engineer
Chemical Oil/Petroleum
Process & LP

Education & Qualifications

University of Louisiana at
Lafayette – B.S Chemical

Aspen PIMS™
Aspen ACCE™
Process Simulations

Areas Of Expertise

Chemical Process
Process Engineering
Refinery Business
Complex Linear
Programming & Modeling


Sean is a chemical engineer with 20 years of experience in downstream optimization. Throughout his career, Sean has consulted on a variety of projects spanning the globe where he gained valuable process engineering experience in the design and configuration optimization of refineries, petrochemical facilities, and other integrated complexes. Sean routinely performed in-depth evaluations via complex linear programming to determine the most appropriate technology to enhance refinery output, balancing CAPEX requirements, infrastructure constraints, and the energy needs specific to each region. Sean’s expertise also spans the renewable energy space, including projects such as Ethanol Biorefineries and Waste-to-Energy facilities.

At OCI, Sean’s industry knowledge is essential for petrochemical and renewable clients as they restore plant equipment and processes following catastrophic events. Sean leverages his extensive linear programming expertise to evaluate the economic impacts caused by disasters to resolve complex refinery business interruption claims.

Selected Assignments

Claims – Description Type Value
Pennsylvania Refinery – Explosion CBI (LP) $200M
Pennsylvania Chemical Manufacture CBI (LP) $91M
Oklahoma Refinery – Freeze PD $13M
Southern US Refinery — Fire PD +BI $40M
Louisiana Refinery – Freeze PD + BI (LP) $36M
Utah Chemical Mfg. – Electrical Damage PD + BI $26M
Wase-to-Energy Facility, Florida — Fire PD + BI (ACCE) $20M
Ethanol Biorefinery, Illinois – Equip. Failure PD + BI $15M
Industry – Description Type
Crude Unit and IGCC Unit Linear Programming
Hydro Cracker, Delayed Coker, Prime G & D Process Engineering
Gas to Olefins Technology Evaluation
Ethane Cracker Expansion Project Process Engineering
PMRB Modernization Project Linear Programming & Process Design




Pennsylvania Refinery – Explosion
A refinery shut down indefinitely after an explosion caused significant damage to the HF Alkylation Unit, impacting numerous refinery stakeholders. The refinery’s supplier declared force majeure, and Sean was engaged to perform an analysis in response to the claimed damages that followed. Sean analyzed the refinery’s “look back” LP model, historical data, and deposition testimony to determine the amount of crude that the refinery would consume, but for the explosion. Sean’s analysis was used to establish the total amount of transportation units required to transport the crude to the refinery during the loss measurement period, resulting in a substantial reduction in claimed losses.

Pennsylvania Chemical Manufacture — Contingent Business Interruption
A chemical manufacturer (3rd largest US consumer of cumene and producer of phenol) claimed damages associated with supply disruptions due to the shutdown of a Pennsylvania refinery and subsequent force majeure. These events significantly impacted contractual pricing agreements and caused the chemical manufacturer to source feed chemical components at spot market prices.

In response to the monetary BI damages, Sean was engaged to provide an independent expert LP planning analysis of the refinery’s production capabilities post-incident. Sean’s analysis included production scenarios to demonstrate the refinery’s level of output, considering the reduced production capabilities caused by the explosion, resulting in a substantial reduction in the BI loss measurement period.

Louisiana Refinery – Freeze
A freeze caused damage to reboiler equipment within a plant’s specialty lube unit, triggering working inventory congestion and process throughput curtailment. The weather-related event caused significant monetary damages requiring an assessment by an independent expert to validate the losses caused by the freeze. Sean performed an analysis to evaluate the general impact of the damage and its effect on the plant’s lost processing capabilities. Sean performed LP modeling using the refinery’s historical data
and daily production volumes to develop the basis for the BI duration period.


Utah Chemical Manufacture – Electrical Damage
A chemical manufacturer’s turbine generator suffered an electrical ground fault causing damage to the plant’s major equipment — resulting in processing complications and a total shutdown. Sean was retained to evaluate the plant’s operation processes to determine if the additional equipment failures beyond the ground fault were related to the initial claim damage. Sean’s process analysis and evaluation resulted in the conclusion of separate non-related damage events.


Arizona Refinery – Equipment Damage
A refinery suffered stripping tower piping damage failure, resulting in a fire and additional equipment damage to the stripper column and reboiler/heater section. Sean provided an analysis of the reboilerheater to confirm the extent of damage to the compromised equipment.



Wase-to-Energy Facility, Florida — Fire
A fire broke out at a garbage recycling plant destroying the fire suppression systems and causing a loss of the plant’s major conveyor systems. The plant’s owner filed a multimillion-dollar claim for property damages and business interruption losses. The plant operator hired Sean to review the project schedule and manhours required to install new conveyor systems, fire suppression systems, and other equipment replacements. Sean developed an estimated schedule to replace the damaged equipment and restore the plant to its pre-incident condition.

Ethanol Biorefinery, Illinois — Equipment Failure
Damages to an ethanol plant’s Volatile Organic Compound (VOC) reduction equipment triggered reductions in the plant’s output due to VOC state limits. Sean was retained to evaluate the process conditions associated with operations including the event mitigation efforts to determine the refineries processing capabilities post-incident.


Refinery & Chemical


Crude Unit and IGCC Unit — Persian Gulf
A client with abundant high-sulfur oil in the Persian Gulf required a solution to generate electricity – to supply power for a large city. The refinery needed to expand crude oil distilling capabilities, allowing the client to sell various fuel components on the open market that were not required to generate electricity. Sean performed a feasibility study using linear programming to determine if future revenues generated from the refined fuel components would offset the capital improvement costs (CAPEX) and ongoing refinery operation costs (OPEX). Using a refinery economics optimization program, Sean proposed developing six different refinery configurations and utilizing a skimming unit to distill the crude.

Hydro Cracker, Delayed Coker, Prime D, Crude Unit — South America
Sean was appointed the lead engineer to perform feasibility studies of a Delayed Coker unit and power plant based on a 20-year cash flow planning window for CAPEX and OPEX. The multibillion-dollar evaluation involved the expansion of necessary off-site infrastructure, ranging from tank farms to utility configurations required to support the ambitious endeavor.

On a separate engagement for a crude tank farm and gasoline blending system revamp, Sean performed the planning of an advanced blending system. This configuration involved a 23-crude blending system based on a 7-day tank farm storage capacity timeframe.

Refinery Process Configuration Validation — Central America
A grassroots expansion project required an additional 22 processing units and offsites. Using linear programming, Sean validated the proposed configuration’s feasibility and the refinery’s financial model to process multiple crude feeds using laboratory raw crude data.

PMRB Modernization Project — South America
Sean worked closely with the client’s planning team to produce a 20-year CAPEX and OPEX financial analysis-based plan for a multi-billion-dollar modernization project. Sean ran numerous scenarios, developed an EPC refinery planning model for 45 units, including the refinery’s crude feed blends, and he optimized the refinery’s new unit configuration.


Gas to Olefins — SE Texas
A client rich in natural gas was interested in expanding their refining capabilities and required an evaluation of three different technologies (OLE3): gas to methanol (GTM), gas to olefins (GTO), and expanding the existing ethylene process. Sean evaluated each proposed technology by comparing the process equipment, utility systems, and auxiliary systems required for each configuration. Sean further analyzed how well each technology would integrate with the facility’s existing equipment. Due to the complexities of the auxiliary and utility systems, along with CAPEX and OPEX evaluations, Sean determined that expanding the existing ethylene process would give the client the best process advantages.

Ethane Cracker Expansion Project — SE Texas
The plant owner was considering three different licensor technologies and required an expert recommendation to select the best technology to fit within their existing plant configuration. Sean was appointed as the lead process engineer to evaluate each technology option and recommend the appropriate intermediates and derivates to execute an OLE3 project.

Ethane Cracker — SE Texas (Process engineering)
A grassroot ethane cracker expansion project required instrumentation detailed engineering and 3D model reviews. Sean led FEED and EPC design activities, including hydraulic reviews, EFD reviews, HAZOP resolution, vendor drawing reviews, and utility balances.

Off Gas Pretreatment Unit Revamp — SE Texas
The owner of a plant was expanding their capabilities to produce petrochemical propylene feed to sell to a nearby polypropylene producer. Sean was responsible for H&MB, simulation work, equipment data sheets, instrument data sheets, and PRV calculations, PFDs, P&IDs.


Merox Unit and Butylene Offsite Revamp — SE Texas
A plant in southeast Texas needed to expand its processing capabilities to complement an upstream refinery that recently expanded its capacity. The plant required two separate processing technologies, one for a butylene plant and the other for a Merox gasoline treatment plant. The original engineers appointed did a substandard performance and Sean was brought on to correct and finalize the engineering design of the multi-phase upgrade.


Delayed Coker Units
During an industry boom period, Sean worked with a world-renowned engineering company to expand delayed Coker plants located in the US, Northern Europe, and South Asia. Sean led engineering efforts to optimize the leftover vacuum residue thereby increasing the volume of fuel products produced. Sean performed various engineering responsibilities, such as developing feasibility studies (conceptual engineering), preparing H&MB, simulation work, creating equipment and instrumentation data sheets, and performing PFDs, P&IDs, and PRV calculations.

Solvent De-asphalting Unit — Gulf of the Caspian Sea
Sean was appointed the lead engineer to implement a new industry technology that produces asphalt and feed for super-critical delayed Coker plants. The client required a grassroots expansion project to incorporate the new technology. Sean performed heat and material balance (H&MB), simulation work, created equipment and instrument data sheets, pressure relief valve (PRV) calculations, process flow diagrams (PFD), and process and instrumentation drawings (P&ID).


Refinery Fuel Transition: The Partial Conversion Approach from Transportation Fuels to Petrochemicals, Hydrocarbon Processing IRPC Americas, September 25 – 26, 2019, Houston, TX, United States


2021 – Present OCI-USA
Houston, TX
Senior Engineer, Chemical Oil/Petroleum Process & LP
2018 – 2020 SNC Lavalin
Houston, TX
Refining Engineer – Downstream Optimization Specialist
2005 – 2018 Foster Wheeler
Houston, TX
Lead Process Engineer