Resume - Process Design and Simulation Engineer

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Resume #47589

CONTACT INFORMATION:
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ACADEMICS:
M.Tech (Chemical) from Aligarh Muslim University in 2000-2002 with 78%
B.Tech (Chemical) from Aligarh Muslim University in 1996-1999 with 73.3%
HSC from Senior Secondary School (A. M. U. Board) Aligarh in 1995 with 74.8%
SSC from Kendriya Vidyalaya (CBSE Board) Faizabad in 1993 with 73.6%

COMPUTER PROFICIENCY:
Technical software's: Hysis, Aspen Plus, Fluent, Chemcad, Design-II, Polymath, STHX, RTD,
Answer, AutoCAD2000.
Operating Systems: Windows 95/98/ME/2000
Programming Languages: C, FORTRAN, MS DOS.,

PROFESSIONAL EXPERIENCE:
February 2005 till date
Reliance Industries Limited
As Manager Process

Job Responsibilities:
* Process simulation and design
* Process Improvement
* Process modification
* Process optimization and process control.

November 2003 to February 2005
United Phosphorus Limited
Executive: Process Engineering

Job Responsibilities:
* Process Development
* Process Modelling & Simulation
* Process Modification
* Process Improvement
* HAZOP Study

Achievements:
* HEDP pilot plant Design, errection, commissioning.
* TPPi Plant expansion
* HEDP plant chloride removal
* TPPi Plant phenol removal

July 02 to October 03
Armour Polymers Ltd.
As Process Engineer

Job Responsibility:
* Responsible for R & D.
* Finding new optimum conditions for different products using different catalysts.
* Making mass & energy balance on each unit and process to find out the yield.

Achievements:
* Installation of boiler.
* Compared performance for distillation column having different packing.
* Compared performance of distillation column over years.
* Pyridine plant throughput increased.
* Assist in designing Heat Exchanger.

December 2000 to May 2001
Aligarh Muslim University
As Lecturer

Job Responsibility:
* Courses taken for Mass Transfer, Reaction Engg. and C programming & Numerical Methods and Lab Courses.
* Attended UGC sponsor Refresher Course as lecturer.
* Guided B.Tech. & M.Tech. students to complete their projects and research

Projects:
* LAB plant project:
Working in Linear alkyl benzene plant as Manager: Process. LAB (Linear Alkyl Benzene) plant, which is an intermediate between refinery and petrochemical complex as it had essentially all the features of both. Full knowledge of Refining, Hydro-treating, UOP Molex process, Alkylation and UOP Pacol technology. Working on heat exchanger rating using Aspen plus. Designing a new column using simulation tool Aspen plus. Working on improvement of compressors, and doing dynamic simulation of column using Hysis as dynamic simulation tool. Process improvement of Molex process by carrying out various parameters of the process using Aspen explorer and applying chemical engineering and statistical principles to reduce the fluctuation (cyclic in nature) of the process.

* TPPA continuous process:
TPPA (Tri Phenyl Phosphate) was produce by batch process. Worked on the process to make it continuous along with R&D personnel, complete mini plant for the reaction was designed and trials were taken, as the real kinetics is not known and most of the parameters were not well established. Pilot plant design and experimental trials planning was done. Rest of the process was established by theory and taking pilot trials in Technoforce Private India Limited which includes equipment like liquid-liquid contactor, falling film evaporator etc.

* TPPi expansion & process improvement:
TPPi (Tri Phenyl Phosphite) was one of our products and it has tremendous potential due to market demand. We produced it in batch mode. Due to increase in market demand we want to produce it continuously. For this I worked on reaction kinetics, pilot plant trials, process-scheme, and development of PFDs & PIDs, Hazop studies selection of operations & equipments and sizing of the equipments. Complete pilot plant was designed, erected and successfully commissioned.

* Kinetics Development:
Development of reaction kinetics according to our need for plant design, experimentation planning, experimentation, data generation and data and regression analysis was done for two products TPPi and HEDP using the regression software POLYMATYH.

* POCl3 Mini Plant DESIGN:
From one of our unit we get crude POCl3 as by-product whose real composition is not known. We distill POCl3 to the required purification and used partly as the end product and partly as the raw material for the other products. For the development of this process a mini plant was designed and successfully run for a week to get the process established. Worked on this process to scale it up for full-scale plant.

* HPED Pilot Plant Design:
HEDP was one of our products made by batch process and we want to produce it by continuous process due to market demand. For this designed the complete pilot plant with completely new process-scheme, and development of PFDs & PIDs, Hazop studies, selection of operations & equipments, sizing of equipments and complete layout was made single handedly. Erection and successful commissioning of pilot plant was done.

* Process Design Of Acetic Acid Distillation:
70% Acetic Acid and water mixture is the feed and the distillate is 20% Acetic Acid and the bottom are 90% Acetic Acid solution. Complete column design including condenser and reboiler was done.

* HEDP Chloride Removal: HEDP
One product has stringent quality norms one of the parameter is chloride content. A new process is developed for the removal of chloride, which reduces the batch time of about 12 hours.

* Flash Distillation Design:
For the removal of unconverted phenol from our product TPPI flash distillation set-up was designed. For better mass transfer a nozzle was used to flash the feed and proper parameters (temperature, pressure and flow-velocity) were selected.

* Simulation For Ethanol-Water Distillation:
Ethanol is used as reactant in one of our product as it is not the limiting reactant and it is used in excess. Moreover, water is also produced with our product so to recycle back we have to separate ethanol from water. Simulation for separation of ethanol-water using Cyclohexane and Pentane as entrainer was done using Design-II simulator.

* De-bottlenecking of Pyridine plant:
Pyridine is made by the gas phase reaction of acetaldehyde, formaldehyde and ammonia in the presence of catalyst. As the catalyst change, space-time required for the required conversion goes down all the pre-heaters and super-heaters were good for the new throughput but the product condensers were become the limiting. So, bigger condensers were design based on new heat duty.

* Transforming Tray Tower To Packed Tower:
A tray column was changed to packed column to increase the performance of the column. As structural packing was used the performance after modification met up to our quality specification. Moreover its capacity was increased as the debottle-neck in that tower was the reboiler and due to decrease in pressure drop across the tower more gas-flow rate could be managed.

* Trials In R&D For Optimum Parameters:
For our new catalysts some trials were made to find the optimum temperature, feed ratio and space velocity. Trials based on factorial design were made and the optimum parameters were selected and successfully implemented in the plant and the plant achieved the highest yield.

* Column Performance Evaluation:
To see the performance of the column when it's packing (pall rings) was changed to structural packing and also the time decay in performance of another column using data-sheets and mathematical tools like curve fitting, interpolation etc.

* M.Tech. Dissertation: Dynamics of Closed Loop Thermosyphon System
General one-dimensional dynamic models for a simple closed-loop thermosyphon have been developed by writing differential mass, momentum and energy balances. The partial differential equations thus obtained are numerically solved with the help of computer using finite difference techniques for two case namely uniform heat flux and uniform wall temperature. The dynamic responses have been obtained for start-up as well as step input in heat flux and wall temperature. The computations were made for an experimental thermosyphon system consisting of a single vertical copper tube connected to separator and vertical and horizontal tubes to form a closed loop circuit. The tube is of 19 mm inside diameter and is heated externally by winding nichrome wire uniformly over a length of 940 mm. The steady state liquid temperature distributions along the tube length at uniform heat fluxes have been computed for numbers of liquids. The experimental data of previous workers at some heat fluxes for liquids have also been presented on the same graphs for comparison. A good agreement ensured the validity of developed models. The dynamic response of fluid temperature, wall temperature, fluid velocity and forces for uniform heat flux start up cases has been presented graphically and there characteristic features discussed. The step-input response over a steady-state operation has also been obtained for fluid temperature. A comparison between theoretically obtained response and experimentally measured one shows a fairly good agreement. In case of uniform wall temperature the steady state fluid temperature distribution along the tube length and variation of fluid temperature, heat flux, fluid velocity and forces developed as a function of time for various fluids were obtained. The results have been presented graphically and discussed.

* M.Tech. Term Paper: Modeling of Tubular Reactors
Tubular reactors are normally used in the chemical industry for extremely large-scale process. When filled with solid catalyst particles, such reactors are referred to as fixed or packed bed reactors. Modeling for the tubular reactor for the homogeneous reaction and for the fixed bed having spherical catalyst is done by the shell balance approach. For the former case the model is simplified up to the simplest model for tubular reactor that is plug flow model. Numerical solutions are presented for differential equations representing the isothermal steady flow tubular reactor with varied degree of back mixing of the reactants in the axial direction and with reactions with order other than zero and first. Optimum temperature progression for a reversible exothermic reaction-taking place in a tubular reactor and an optimum pressure gradient for a reversible gas phase reaction where the number of moles increases with extent of reaction is discussed. Lastly, in the sequence of operation that leads to the design of full-scale chemical plant techniques using statistics and an electronic computer can generate a comprehensive model of the full-scale plant. The model is built up in stages. To this is added at the semi-technical stage a set of terms based on the relevant scale-dependent physical and engineering factors. To complete the simulation, a set of perturbations is added corresponding as far as possible to the incidents of full-scale plant operation and to the proposed flow of materials through the plant.

* B.Tech. (Final) Project: Prediction of Vapor-Liquid Equilibrium by Using Group Contribution Methods
To illustrate the importance of VLE data it is enough to say that it is use in the design of distillation column. To determine constant pressure VLE data software has been developed. It predicts constant pressure VLE data for binary and multi-component system by using group contribution methods for calculation of liquid phase activity coefficients. The software, developed in C programming language on MS-DOS operating system, allow user to choose among UNIQUAC and UNIFAC methodology for predicting VLE data. UNIQUAC is restricted to binary systems while UNIFAC can be used for binary and multi-component systems. The software developed was quite useful and it is use by our juniors to predict the VLE data for there system and based on this the design calculation for the columns are done.

* B.Tech. (Final) Design Project: Techno Economic Feasibility Report on Production of Ethylene from Liquefied Natural Gas
The project involved preliminary process design of major equipment used in production of ethylene. The preliminary cost estimate was also done. The project was an exercise to implement the chemical engineering principles learnt at the college level to a realistic and holistic problem.

* B.Tech.(Pre-final) Seminar: Ion Separation by Bipolar Membrane in Reverse Osmosis
A literature survey was done seminar was delivered and a report was made, this project teaches the students how to work in a field which is developing and didn't have a complete shape yet. This basically deals with Bipolar reverse osmosis membrane that have both negative and positive charged layers have been prepared to enhance the selectivity towards both mono and divalent ions in respect of both cations and anions.

TRAININGS/SEMINARS/SPECIAL ASSIGNMENTS:
* Three days training on Aspen Plus by Aspen Tech.
* 'Introductory Fluent & Gambit Training' (Aug 16th-20th, 2004) organized by Fluent India Private Limited for Five days
* Course on 'Intensify The Profits Through Process Intensification' jointly organized by Indian Chemical Manufacturers Association and Indian Institutes of Chemical Engineers.
* Participated in Refresher Course in subject 'Advances in Chemical Engineering' as Lecturer, Aligarh Muslim University, Aligarh.
* Vocational Training at Indian Oil Corporation Limited (IOC), Barauni
* A month Course done in C-Programming (Oct 1997) by Institute of Computer Literacy (ICL).

Personal Details:
Available upon request

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