Senior Production Specialist - Chlorinated Methanes/Ethanes Plant - Chlorinated Organics Business
The Dow Chemical Company
Total years of experience :6 years, 1 Months
The Dow Chemical Company, Freeport, Texas
Senior Production Specialist - Chlorinated Methanes/Ethanes Plant - Chlorinated Organics Business
Hydro Chlorination, Thermal Chlorination & Waste Water Treatment Operations (Nov ’10- Present)
• Responsible for the safe and reliable operation of the Hydro Chlorination & Thermal Chlorination reactor systems, including refrigeration system, distillation sections, Thermal Oxidizer Units, Non Biological treatment and all associated infrastructure.
• Utilized Six-sigma principles to collect data, analyze and make changes to improve performance of the Hydro Chlorination Catalyst.
• Developed expertise in Vapor phase & Liquid phase reaction. Improved Hydro liquid phase conversions and overall capacity and catalyst lifetime by 8 Months.
• Identified Process control improvements to improve Operational reliability of the Hydro & Thermal Chlorination process.
• Optimized Methyl Chloride, Methylene Chloride & Chloroform distillation columns increasing capacity by 15%.
• Operations Turnaround coordinator for $8.3MM turnaround. Responsible for scheduling, production & maintenance planning, cost control, change approvals, and plant start-ups.
• Responsible for all aspects of the $800M Caustic Scrubber Improvement/replacement project including scope definition, design, budget, construction & start-up.
• Led Lined Pipe Improvement Team, implemented a new Lined pipe Maintenance strategy for the plant and reduced unplanned events caused by lined pipe failures by 20%.
Run Plant Engineer - Salt Dome Operations - Mining/Storage/Pipeline Business
Brine Mining & Storage Operations
• Responsible for the safe and reliable operation of the brine assets, including brine mining caverns, clarifier caverns, storage & treatment ponds, brine strippers, Storage caverns and all associated infrastructure.
• Led multiple energy reduction projects for the plant which resulted in reducing 5% energy consumption and an annual savings of $250, 000.
• Completed sump development of two mining caverns and initialized the Sump development of the third cavern, delivering $450 M/day in chlorine capacity.
• Created Cavern models for Mining & Storage caverns and tracked the predicted & actual pressures on the caverns which were leveraged to the MSP tech center.
• Identified design flaw in DW-17 cavern internal pipe settings and implemented corrective changes in the field which prevent a pre-mature failure of a $25MM new asset.
• Improved the operating discipline around Storage Cavern packers and placed a packer program for the Plant
• Worked with the Mining/Storage & Pipeline Technology Center to secure process data for identification of technology gaps, improvement opportunities, and project definitions as well as Most Effective Technology (MET) implementation. Key player in analyzing, building and justifying the economics and cost models for initiating new process improvements and projects.
• Practiced (DMAIC) six sigma techniques to ensure product quality and estimate process capabilities. Performed DOE, regression and R-r studies to define corrective and preventive actions. Improved asset capability by 5%.
• Identified process control gaps in the current system, developed new process control strategy documents with automation group to improve the quality of operations and to maintain long term asset capability. Reduced Nuisance alarm frequency by 25% and I/O’s in Manual by 14%.
Improvement Engineer ( Brine Mining & Storage Operations) (Feb ’07- Sept ’08)
• Project Manager for several capital projects $100M-$350M.
• Manufacturing Representative for capital projects $100K to $2.8MM.
• Converted the Ethylene Heater system at SDO from PLC to MOD V and reduced unplanned events on the Heaters by 25% and Title V deviations by 10%. Completed the Project safely, on-time and on-budget.
• Plant focal point for R&D Tax credit submission for capital projects.
Process Engineer
• Formulated and evaluated environmental friendly bio degradable scale and corrosion inhibitors for field applications.
• Continued trending and analysis of production and performance parameters.
• Handled Process start up and shut down operations effectively.
International Truck & Engine Corporation (Navistar International)
Indianapolis Engine Plant, Indianapolis, Indiana (Mar ’06- Sep ‘06)
Chemical Engineer
• Provided technical support regarding the application and selection of metal working fluids in cutting and grinding operations.
• Resolved process problems, improved plant operations and coordinated the evaluation of changes.
• Supervised the activities in waste water treatment facility. Responsible for arranging proper disposal of hazardous waste and ensured that the plant environment complies with OSHA & EPA regulations.
Manufacturing Engineer
• Designed and optimized in-house heat treating processes. Maintained engineering heat treat standards and internal operations heat treat process documentation.
• Analyzed heat treat process failures developed and implemented corrective actions.
• Technical resource for hourly operators and responsible for supervision and scheduling.
Masters (Chemical Engineering) (Fall ’03 – Fall ’05) Illinois Institute of Technology, Chicago IL GPA – 3.3/4.0
➢ Bachelors (Chemical Engineering) (Aug '99 - May '03) University of Madras, Chennai, India GPA - 3.8/4.0