Sushil Kumar Rao

HMEL has setup an integrated petrochemical block within the existing refinery complex(11.3 MMTPA) having capacity of 1.2 MMTPA Dual feed cracker unit to produce polymer grade Ethylene and Polypropylene for 800 KTPA of LLDPE(UNIVATION TECHNOLOGY), 450 KTPA dedicated slurry phase of HDPE (CP-CHEM-MARTECH), 55 KTPA OF Butene-1(AXEN) and 500 KTPA of PP(LYONDE BASELL).
LLDPE/HDPE SWING unit has 2*400 KTPA capacity comprises of two identical polymerization and Extrusion trains each of 400 KTPA capacities (Train-1 and Train-2) with single battery limit and common feed purification section and separate polymer handling and storage facilities of two trains.

Job Profile and Responsibilities:

● Spearheaded the pre-commissioning, commissioning, startup, and stabilization phases of a state-of-the-art PE Swing Petrochemical LLDPE plant employing Univa-tion Gas Phase Technology
● Successfully run UCAT-J(Z-N Cat)and UCAT-G (Chrome Cat) with all grades of prod-ucts. Preparing for Metallocene and BMC catalyst run.
● Lead shutdown activities, including equipment isolation, cleaning, and mainten-ance, ensuring minimal downtime and adherence to maintenance schedules
● Hand on commissioning and stabilization of major rotator equipments like CGC, VGR, N2 and Refrigeration, AREZEN Resin and Pellets compressor
● Handle minor and Major Shutdown and startup including emergency shutdown.
● Implement strategic initiatives PSM prompt checklist and PSI to improve production efficiency, reduce costs, and enhance product quality.
● Lead cross-functional teams to troubleshoot and resolve technical issues, ensuring minimal downtime and optimal plant performance.
● Develop safety habits and implement safety procedures to uphold a zero-incident culture, resulting in a significant reduction in workplace accidents.
● Collaborated with senior engineers and managers to optimize process parameters and enhance production efficiency.
● Conducted routine process monitoring and data analysis to identify areas for im-provement.
● Participated in safety drills and emergency response simulations, contributing to a culture of safety awareness.
● Contributed to the development of standard operating procedures (SOPs) for vari-ous units’ processes.
● Implemented and optimized processes to improve plant efficiency, reduce down-time, and enhance overall production output.
● Analyze process performance regarding technical progress of MOC.
● Coordinated with cross-functional teams, including engineering, operations, and maintenance, to streamline project timelines and deliverables.
● Conducted thorough risk assessments and participated in HAZOP studies to identify and mitigate potential operational hazards
● Executed comprehensive pre-startup safety reviews, contributing to the successful and timely commencement of plant operations

BCPL has set up 280KTA of dual feed cracker unit of Lummus Technology USA, 220 KTPA of LLDPE by INEOS Gas phase Technology-UK and 60 KTPA of Polypropylene (PP) Novolen Technology (Stirred gas phase reaction) -Germany. Products include 55.7 KTPA Pyro-Gasoline and 12.5 KTPA Fuel Oil.
Job Profile and Responsibilities:
● Led precommissioning, commissioning, startup, and stabilization activities of LLDPE swing plant, overseeing equipments readiness and coordination with cross functional and Licensor.
● Monitoring of key parameters to improve run length with desired specification of product and improved process operation.
● Preparation and review of operational, Start-up, shutdown and Grade transition procedures.
● Implemented continuous improvement initiatives to optimize plant performance and reduce operating costs.
● Successfully resolved technical challenges during the startup phase, optimizing pro-duction rates and minimizing downtime.
● Provided technical training to operations and maintenance teams, fostering a culture of knowledge-sharing and skill development.
● Collaborated with cross-functional teams to ensure seamless integration of project phases and adherence to safety protocols and environmental standards.
● Developed and implemented operational procedures and protocols for efficient plant operation and product quality control.
● Led a team of engineers and technicians, providing mentorship and fostering a culture of continuous improvement.

IGL produces Ethylene Oxide (EO) / Mono Ethylene Glycol (MEG) from renewable agro route based on molasses, since 1989. Leading manufacturers of Glycols, Ethoxylates, Performance Chemicals, Glycol Ethers & Acetates, Guar Gum and Potable Alcohol. It has set up its Ethylene glycol plant in technical collaboration with Scientific Design Inc, USA. The plant produces three derivatives of ethylene glycols.Mono ethylene glycol (MEG), Di ethylene glycol (DEG) and Tri ethylene glycol (TEG).

Job Profile and Responsibilities:

● Successfully led day-to-day operations of the MEG plant, ensuring optimal produc-tion efficiency and adherence to safety standards.
● Played a key role in the startup and shutdown of the MEG plant, overseeing equipment readiness and coordinating with cross-functional teams.
● Collaborated with maintenance teams to plan and execute turnaround activities, optimizing the efficiency of the plant during shutdown periods.
● Implemented continuous improvement initiatives to enhance the overall efficiency of the MEG production process.
● Conducted root cause analysis and implemented corrective actions to address op-erational challenges and improve process reliability.
● Ensured compliance with environmental, health, and safety regulations, conducting regular audits and inspections to maintain a safe working environment.
● Provided technical support to operations teams during routine and non-routine plant activities.

IRSL is an integrated composite polyester complex producing Polyester staple fiber (PSF), POY, DTY, Chips. Plants have been set-up in technical collaboration with ZIMMER technology of Germany.

Job Profile and Responsibilities:

● Managed day-to-day operations of a polyester plant, by continuous monitoring of specified process parameters. Handle shift independently by using optimum man-power with proper planning and scheduling.
● Implemented process optimization strategies, resulting in an increase in production efficiency.
● Collaborated with cross-functional teams to troubleshoot and resolve operational issues promptly.
● Conducted regular safety audits and implemented safety protocols, achieving a zero-incident record during the tenure.
● Monitored and maintained process parameters to meet product quality standards and customer specifications.
● Coordinated with maintenance teams for equipment inspections, repairs, and pre-ventive maintenance activities.
● Conducted training sessions for plant personnel on safety, operational procedures, and troubleshooting techniques.

Job Profile and Responsibilities -
● Production of Polyester chips of various grades of bright, semi bright, full bright etc with operating crew with proper planning and scheduling
● Led start-up and shutdown activities, ensuring a smooth transition between production phases.
● Worked closely with QC team to ensure product specification with consistency.
● DCS monitoring of unit process of DMT melter, Trans Etherification reactor and Polycondensation reactor
● Dedicated Ethylene glycol Recovery (Distillation Process) system.