Expert in Process Plant Design and De-bottlenecking, Gas Phase Polymerization and Material Handling
Expert ID: 728737 India
Expert has applied his process engineering knowledge to improvements, optimization, trouble-shooting and projects in chemical and petrochemical plant operations in order to deliver direct monetary benefits. His technical expertise in process industry spans both small batch units to world-scale continuous processes each demanding unique skill sets.
Through strong analytical skills, effective application and implementation of solutions he has built un-paralleled expertise in process plant operation and optimization. An in-depth understanding of key operating and design parameters which influences quality, quantity and steady operations has enabled him to provide solutions such as fluothane column de-bottlenecking resulting in reduced batch cycle time and increased throughput by 50%.
Expert has conducted Energy Conservation audits for naphtha based fertilizer unit and has identified and implemented technology upgrade projects resulting in energy savings in excess of 20%. He has been responsible for process validation and yield improvements in agro and pharma businesses where he achieved batch cycle time reduction of 20% by de-bottlenecking rate limiting batch distillation section.
Besides core process engineering applications he has demonstrated analytical capability in supply-chain optimization and production planning improvements which has introduced successfully new concepts such as being ‘right first time’ and ‘zero waste’.
Expert has authored 50 technical reports on petrochemical plant operation improvements, simulation, trouble shooting and problem analysis. Through use of IT tools, he has developed databases to monitor plant, equipment and process performance and to support technical analysis with meaningful data.
He has initiated a structured approach to plant performance and reporting which has been adopted as part of plant-wide ISO procedure. He has been instrumental in solving key guarantee related problems of load cells as he identified the relation between Mix vessel jacket temperature changes and load cell variations. This load cell variation was part of Guarantee item being addressed by reputed vendor who praised the expert for his problem solving ability.
With hands-on experience of process and equipment design specifically in the polyolefins industry Expert has successfully defined the complete scope and specification of a $250 MM, complex revamp project including utilities and relief system for polypropylene plant capacity upgrade. Realizing importance of value engineering at early stages of project development, he has successfully incorporated process changes at basic design which have realized benefits in excess of millions.
Expert has reviewed licensor prepared process design package in line with site conditions and requirements. At the FEED stage he has conducted complete utility and power balance to identify and define scope for utilities. At each stage of design he has implemented value engineering proposals including incorporation of operational flexibility, integration of process streams resulting in cost savings and up-rating of existing equipment for higher load. In particular, use of inter-connecting process lines between two recovery sections has resulted in published savings of $5.8 MM.
He has also developed PFD, P&ID including interlocks and controls for an oil recovery coalescer project which was essential for financial closure and banker’s acceptance. He has been the technical authority in matters legal and contractual.
Expert has implemented a fast-track modification of H2 supply to polypropylene reactors. Modification included provision and sizing of an additional low flow control valve (Fisher-Bauman) and thermal mass meter (Bronkhurst) to enable special grade production. Prepared P&ID, provided tie-ins, conducted HAZOP and commissioned the line and system successfully. He has followed-up with a project evaluation report.
Expert was assigned for complete technology transfer for Methyl methacrylate polymerization plant and an acrylic cast sheet plant. In addition to technical know-how he has prepared the FEED package for the same based on site conditions and basic technology.
Starting at an early stage in his career he has developed projects from concept to commissioning, from technology upgrade projects which have resulted in energy savings to fast-track oil scrubbing towers. He has designed modification, including PFD & P&IDs development, to existing production units that has expanded the capabilities of the plant to produce additional grades.
Expert has spent that last decade in two of the leading gas phase polyolefins technology covering polyethylene and polypropylene. Through operation & problem evaluation, analysis and a thorough understanding of design principles and basis he has developed un-parallel expertise in these technologies.
Expert has mapped the complex relation of various polymerization reactor control parameters against production quality and quantity. This has established a useful tool for operation and technologist to manage reactor control and continuous operation.
He has implemented nuclear level instrument calibration procedure.
Expert prepared a detailed Case Study for BASF, Germany on use of their versatile CO removal catalyst which enables end user to reduce their polymerization catalyst usage. CO in propylene is an irreversible poison, even at very low ppb levels, for a Ziegler-Natta catalyst used in polypropylene (PP) polymerization.
For BASF this project provides them with a value added performance review and actual operating experience from the largest single site PP producer.
The project involved study and extensive data analysis of performance, process and project development that led to a successful implementation and commissioning, actual economic feasibility study and operating experiences.
|Year: 1992||Degree: MS||Subject: Chemical Engineering||Institution: University of Kentucky|
|Year: 1990||Degree: B.Tech (Hons.)||Subject: Chemical Engineering||Institution: Indian Institute of Technology|
|Years: 2010 to Present||Employer: Undisclosed||Title: Founder, Entrepreneur||Department:||Responsibilities: Polymer technology expertise with strong process design, project and operation optimization skills.|
|Years: 2003 to 2010||Employer: Saudi Polyolefins Co. (TASNEE)||Title: PP Expansion Supervisor||Department: Technical Department||Responsibilities: As Process supervisor and technology expert, Expert was responsible for the process development and implementation of expansion-cum-debottlenecking project of polypropylene plant. In addition to this, Expert had the responsibility as technology and process expert for plant performance improvement and trouble-shooting.|
|Years: 1997 to 2003||Employer: Eastern Petrochemical Co (Sharq)||Title: Process Engineer||Department: Polyethylene Operations & Process Engineering||Responsibilities: Area engineer for two gas-phase fluidized bed Dow’s (formerly Unipol) Polyethylene plants, Reaction and Catalyst Unit. Specific expertise includes trouble-shooting, cost reduction and de-bottlenecking.|
|Years: 1997 to 1997||Employer: ICI Acrylics||Title: Project Engineer||Department: Project Engineering||Responsibilities: Prepare process section of front-end engineering design (FEED) package for poly methyl methacrylate (PMMA) and acrylic cast sheet plant.|
|Years: 1993 to 1997||Employer: ICI India Limited||Title: Process Investigation Manager||Department: Process||Responsibilities: Responsibilities included validation, yield improvement, preparing and executing energy savings projects from concept to commissioning.|
|Years||Country / Region||Summary|
|Years: 2005 to 2007||Country / Region: Netherlands / Europe||Summary: As a client nominated technology expert, he has supervised, reviewed and given final process approval for a complex revamp of Polypropylene plant at a major international EPC Contractor.|
|Awards / Recognition|
|'Special Mention' at the 'Innovation, Creativity and Excellence in Technology Award', 1997 held at ICI plc, U.K. for contributions worldwide.
Effort : "Debottlenecking Fluothane Distillation".
|Publications and Patents Summary|
|Expert a has published the thesis for his Master degree at University of Kentucky.|
|Training / Seminars|
|In-house training has been delivered on regular basis for the benefit of young engineers.|
|Other Relevant Experience|
|Expert is skilled in use of simulation tools such as Aspen and ProII for material balances, process and equipment design, and equipment rating.|
|English||Expert is very fluent in written and verbal communication in this language.|
|Arabic||Expert can fluently read Arabic and can communicate with lower level of proficiency in this language as well.|
|Hindi||Expert can communicate in this language too.|
Fields of Expertise
chemical manufacturing facility evaluation, competitive chemical production analysis, debottlenecking, petrochemical operations, petrochemical process plant designing, chemical process design, continuous polymerization, polymerization reactor control, polypropylene plant technology, olefin polymerization, polymerization reactor, chemical plant start-up, chemical process control instrumentation, petrochemical process, petrochemical process-engineering equipment, polypropylene polymerization, chemical process safety engineering, chemical plant layout, chemical process economics, chemical process, polymerization, multiphase polymerization, bulk polymerization reactor