Expert Details

Expert in Process Design & Optimisation, Scale-up Engineering, Detailed Engineering, Plant Trouble Shooting

Expert ID: 725828 India

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Over the last 18 years of existence, Expert has carried out designs for chemical plants that start with preparation of conceptual flow diagrams, process flow diagrams, mass and energy balance diagrams, P & IDs, General Arrangement drawings for fabricated equipment, equipment layout drawings including piping isometrics, laying down standard operating procedures, etc.

For processes that have been developed through studies in the laboratory scale, Expert has been instrumental in scaling up to the pilot plant scale and finally to commercial levels. Chemical Plant designs are carried out based on well established data that either generated through small scale or bench scale studies or are based on data provided in the literature.

Specific emphasis have been given by Expert to ensure that any reactor that is designed to carry out a chemical reaction which invariably involve exothermicity or endothermicity, perform optimally at the conditions desired. It has been quite a challenge to optimize designs of chemical reactors in the commercial scales, in order to match the yields, conversions, and cycle-times as achieved in the lab or pilot scales of operation. Quite often, batch reactors have been converted to continuous reactors involving the CSTR protocol.

The designs for chemical reactors usually have been arrived through data generation in small scale reactors. Chemical reactors designed by Expert has sometimes followed the principles of micro-reactors where the primary feature has been to increase the surface area to volume ratios.

He has had probably the most satisfying experience that he has gained through his assignments has been the one in UK where an energy efficient drying system has been designed for a coating machine. The heat of combustion in the evaporated organic solvent from the drying system has been utilized to replace 95 % of the natural gas that would have otherwise been used as the source of energy for drying. This assignment has helped the client in securing a few prestigious awards by the Scottish Government for energy conservation.He provided detailed analysis of the heat transfer aspect of a chemical reactor where the organic product, an aroma ingredient, was being co-distilled under high vacuum, resulted in identifying the limiting heat transfer coefficients. Steps were taken to improve the limiting heat transfer coefficients and also the heat transfer area, which ultimately helped in reducing the batch-time which in turn helped in improving the yield due to shorter residence time of the product in contact with the hot surfaces.He worked on the trouble-shooting of a non-performing plant to produce Polyester Resin by analysis of operating data helped in the plant operating with reduced batch time, reduced energy consumption and hence reduced manufacturing cost. This was for a Client in Oman. Expert has recently helped a Global R & D Centre in setting up a high pressure lab to carry out simulated corrosion studies using hydrogen sulphide as one the principal gases. This project involved attaining extremely low leak rates of helium through the gas tubing system. This Project involved designing dry-type absorption system for hydrogen sulphide. In the second phase, the set up is being designed to help tests being carried out with the gas mixtures at 350 bars. He has an assignment to carry out basic design, detailed engineering, project engineering and project management of a plant in Saudi Arabia to produce ground calcium carbonate from limestone.


Year Degree Subject Institution
Year: 1976 Degree: B. Tech Subject: Chemical Engineering Institution: Indian Institute Of Technology, Kharagpur, India

Work History

Years Employer Title Department Responsibilities
Years: 1987 to Present Employer: Undisclosed Title: Chief Consultant & Proprietor Department: Responsibilities: He started this consulting firm in 1987 at the age of 34 years, laying his hands on trouble-shooting small chemical plants and helping the industries in increasing their productivity, improve quality, reduce wastage, reduce batch cycle time increase energy efficiency, etc. with a first-principle approach. He has trouble-shooting experience duly supported by strong design-base. He helped his company to move ahead with setting up chemical and process plants on a strong design base.
Years: 1985 to 1987 Employer: Title: Manager-Development Department: Responsibilities: He designed and trouble-shot continuous fluidized bed dryers for black and green tea.
Years: 1981 to 1985 Employer: Title: Research Associate Department: Responsibilities: He worked in the development of coconut shell charcoal as a substitute for raw petroleum coke in silicon carbide manufacture; he also worked in the collection of Carbon monoxide gas evolved during production of silicon carbide and its utilization in manufacture of formic acid.
Years: 1976 to 1980 Employer: Title: Scientific Officer Department: Responsibilities:

International Experience

Years Country / Region Summary
Years: 2005 to 2008 Country / Region: United Kingdom Summary: Helped client in UK in designing an energy efficient drying system for their coating machine used for flexible packaging. The project involved design of drying system, developing algorithm to operate SCADA for process operation under optimized condition, recycle control through on-line mass and energy balance, etc. Utilizing the heat of combustion in the solvent laden air helped the company save substantial consumption of natural gas. This project helped the client in securing a few awards from the Scottish Government towards energy conservation.
Years: 2004 to 2004 Country / Region: Oman Summary: Helped client in trouble-shooting a plant to produce polyester resin. The cause for extremely low rate of etherification was identified. Necessary modification was carried out in the plant which resulted in the cycle time to be reduced. Cost of production was thus brought down to make the plant in a viable manner.
Years: 2005 to 2007 Country / Region: Turkey Summary: The drying system for a rotogravure printing machine was designed by Expert. This system was designed, engineered and commissioned and the results were found to be better than similar machines from Italy that was operating in the client’s premises.
Years: 2007 to Present Country / Region: United Arab Emirates Summary: He was awarded an assignment by a client in UAE who engaged Expert's services to prepare a Feasibility Report for the manufacture of Isopthalic Polyester Resins. Having prepared and submitted the Feasibility Report, Expert has now been engaged in carrying out the basic engineering for the plant.
Years: 2008 to Present Country / Region: Saudi Arabia Summary: He worked on an assignment to design, detail, and project management of a plant to produce 30 tons per hour ground calcium carbonate.

Additional Experience

Training / Seminars
He has conducted inter-active seminars in educational institutions to spread awareness about the role of engineering design and process optimization in the Industry.
Vendor Selection
On a need basis, he undertakes the responsibility to identify capable and cost effective vendors who can manufacture process equipment and set up plants on the basis of design and drawings which his firm provides.
Marketing Experience
He is excellent at approaching a problem with an open mind and with a calculated design based approach has often helped in identifying bottle-necks in a chemical factory set up.
Other Relevant Experience
Expert turns out complete 3-dimensional drawings with piping isometrics that helps in smooth installation of the projects with reduced wastage and minimum interference requiring correction and re-installation.

Fields of Expertise

chemical plant design, chemical process design, pilot plant scale-up, chemical reactor design, chemical reactor scale-up, chemical industry, compressed gas storage, compressed gas handling, compaction, dryness, chemical plant operation, powder drying, particle-size reduction, liquid cooling, organic compound manufacturing, ore processing, corrosive gas, chemical reactor control, liquid dispensing, chemical reaction engineering, chemical plant start-up, chemical process control instrumentation, chemical process equipment evaluation, chemical process equipment selection, chemical process equipment designing, chemical process equipment, chemical plant management, residence time, chemical processing plant, chemical manufacturing facility evaluation, chemical process development, grinding (comminution), chemical separation, chemical plant layout, chemical process economics, duct, chemical plant, chemical process safety management, steam-jet ejector, chemical-process flow chart, chemical process analysis, chemical processing plant design, chemical plant cost estimation, particle-size enlargement, comminution, chemical reaction, chemical precipitation process, distillation, chemical process safety, mixer, solvent extraction, chemical processing, compressed gas, dry fine powder agglomeration, separation, chemical process, chemical kinetics, crusher, fluidized bed, liquid storage, food spray drying, pipe, mixing, liquid pumping, liquid mixing, liquid handling, heat, grinding mill, gas handling, food drying, crushing, compressor (machine), chemical reactor, chemical process heat exchanger, chemical process control, chemical engineering, batch reactor

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