Muhammad I. Email & Phone Number

Jubail Industrial City, Eastern, Saudi Arabia

Successful development, implementation, and stewardship of the Operations Group's strategic planning and KPI reporting process.Facilitation of Operations Leadership engagement in Quality Management System processes, ensuring alignment, addressing challenges, and fostering a culture of continuous improvement.Developing dashboards and analytical tools to provide insight into group performance, enabling data-driven analysis and highlighting key priorities.Focusing on delivering consistent and high-quality products or services that meet or exceed customer expectations.SOPs (Standard operating procedures) development and deployment.Development and implementation of technical training policy within the group and worked as key member of the technical training review committee.Root cause analysis (RCA) techniques training including Fish bone and 5 whys within different departments. Coordination with different licensors to improve plant practices and perform different RCAs.Benchmarking of processes through licensors and experts for continuous improvement in the efficiency numbers.Utilizing data and performance metrics to make informed decisions, identify areas for improvement, and track progress.Development of technical monitoring plan for the plant site and organized plant review meetings to analyze pant performance and take the key decisions.Development of process safety Lis, incident investigation criteria and procedure and other standard organization policies.Mentoring different team members for ongoing development.Coordination and preparation of the corporate plan for the whole group including all the plants.

Karachi

Process engineering manager of Chloralkali, power plant, utilities and EDC/VCM.Worked on revamping Process safety information package for complete site.Conducted Design modifications evaluation and execution to enhance safety, reliability, and efficiency of plant.Worked on production planning, variable cost planning, investment planning on yearly basis.Dealing with licensors of different units to keep the plant operations up to date.Benchmarked processes through licensors and experts for continuous improvement in the efficiency numbers.Performance monitoring of Power plant and maintained efficiency through multiple interventions.Process parameters monitoring and troubleshooting of plant issues.Managed the team of engineers through standard competency model.Presented multiple papers in conferences like Chlorine institute and Oxyvynals.Troubleshooting of Oxy vent recycle reactor (OVR), EDC cracking furnaces problems. Implemented process monitoring matrix with daily, weekly and monthly performance reports. participation in conferences like Chlorine institute, Oxy Vinyl's know how conference and read different papers on ChlorAlkali plant issues, oxy reactor performance and VCM furnace issues.Project lead for the execution of 130 m3/hr effluent treatment plant (ETP).Project lead in the feasibility of hydrogen peroxide plant and zero gap conversion of electrolyzers.Worked on developing and execution of different long term reliability projects at site.Digitization through Advance process control using PRO MV, digital twin on VCM unit.

Karāchi, Sindh, Pakistan

Did feasibility to find out solutions on water and power for the chlorovinyl complex. Evaluation of Coal Power Plant, Renewable hybrid energy solutions.Evaluation of water intake system and recovery from Sea and effluent recycling plants.Feasibility of new downstream products for Chloralkali and polymer chain.Closure of hydrogen peroxide plant feasibility and selection of technology licensor.

Complete integration of new plants with existing running plant.Hydraulics of lines and additional pumps for the utilities needed for new facilities.Basic design Engineering correspondence with the technology providers.Basic design package (BDP) review, Process Hazard analysis (PHA) and closure of all the recommendations.Detail design engineering partner selection for multiple projects.Detail design review and HAZOP of different projects.Support in construction and commissioning of plant.Integration, engineering and construction of Caustic flakes plant, sulfuric acid recovery unit, effluent treatment plant, heat exchangers upgradation and hydrogen peroxide plant.

Karāchi, Sindh, Pakistan

Daily monitoring of Chlor-Alkali plant operational parameters.Preparation of daily and monthly progress reportsTechnical monitoring of plant and report compilation on quarterly basis.Process design specifications using simulation software like ChemCad & Aspen plusCompressor and chiller’s performance monitoringElectrolysis units performance analysis as per licensor guidelinesHCL and sodium hypochlorite manufacturing units monitoring What if analysis, HAZOP, PHA and RCA as per DUPONT guidelinesWeekly presentations and design review on modifications and new process additionsStrong vigilance on quality and inventory management of raw materials and productsChemical inventory and raw materials management.Attended process hazard analysis sessions to analyze the existing hazards of system and proposing recommendations against them through different techniques i.e. WHATIF, HAZOP etc.Involved in preparation of yearly corporate plansShutdown planning and active participations.

Karachi Pakistan

As a Process Engineer, responsible for preparation of Process Design Packages (PDP) and Front End Engineering Design (FEED) studies, for clients. Typical key tasks;o Design Requirement documentation o Feed stock characterization ; Methane yields, constituents analysiso Process configuration customized for end usage and applicationo Detailed Material and Energy balance calculations for the entire processo Biogas conditioning system design (scrubbing, dehumidification and compression)o Parametric modelling of the entire process to define design process conditionso Process Equipment Sizingo Block Flow Diagrams and Process Flow Diagramso P&ID markups along with control philosophyo Plot planso Development of equipment specification sheetso Compilation of the calculations and specifications in a report formato Cost estimates to support the PDP / FEED studies Plant Operations (Extended assignment at a Bio-refinery in Edmonton Canada):o Line tracing of the entire facilityo Revision and update of PIDs for compliance with as built configurationo Biogas plant operationso Lab tests of process sampleso Development of log sheets to capture key plant datao Development of KPI’s to assess plant performance Research and Development:o Literature review to characterize substrates for unique applicationso Benchmark Anaerobic Digestion technologies for size, cost and applicationo Design and Costing of a Dry Fermentation Biogas plant o Design of a pilot scale Ammonia Stripper / Absorber system for Ammonia recovery from process water effluentso Study and design of Methane enrichment systems for biogaso Feasibility study of integration of a Pyrolysis facility with a biorefinery. Client Interaction:o First level engagements with clients and external agencies to obtain requirementso Liaison with regulatory authorities for feedstock estimation

Lahore Pakistan

Worked as a Process Engineer on Calcium chloride, Bleaching Earth and Zinc Sulphate plants. Optimized different operational parameters resulting in increased production.o Optimization of fluidization process to improve Prill quality of Calcium Chlorideo Control of Coagulation and Flocculation operationso Handling of evaporation process with different type of heat exchangerso Working Experience on reactors, dryers and filterso Preparation of daily progress reports on process and production, for the managemento Routine Analysis of process operational parameterso Control of bagging, stacking and loading of final Product in an efficient wayo Stock handling of all the raw materialso Documentation of EMS and QMSResearch and development:o Optimization of the Slurry Ball Mill design, resulting in improvement of mesh sizeo Calibration of different Storage tankso Cost evaluation and feasibility of Coal Fired Furnace o Design of Packed tower scrubbers to absorb CO2 from HCL VaporsKey Achievements:o As a key user of SAP, development of Production planning moduleo Changed the HCL concentration criteria for the reaction which resulted in increased production of plant from 50 MT/day to 90 MT/day.