👨‍💻 Professional Summary

Dynamic and results-driven Process Engineer with over 5 years of cross-industry experience in process modeling, simulation, optimization, and digital twin development. Proven expertise in leveraging AI/ML, Python automation, and cloud-based deployment to deliver energy efficiency improvements, cost savings, and operational reliability for global clients in oil & gas, chemicals, desalination, and power sectors. Strong background in front-end and detailed engineering design, process safety, and techno-commercial project delivery. Passionate about sustainable engineering and digital transformation in process industries.

🚀 Work Experience

Aleph Technologies Pte Ltd.

Process Modelling Engineer | Feb 2023 – Present | Singapore (Remote)

Evonik – Methionine Crystallization AI/ML Predictive Model (Germany/Singapore)

Developed an AI/ML-based predictive monitoring system using historical DCS/SCADA data to forecast solid accumulation and vacuum loss in crystallizers, reducing unplanned shutdowns.
Engineered a dual-rate accumulation model incorporating pressure spikes, enthalpy changes, and flow dynamics to differentiate between normal and aggravated fouling regimes.
Introduced an Accumulation Index (AI) for real-time risk scoring, enabling proactive flushing alerts and reducing operator response time by 40%.
Collaborated with plant operations to validate model accuracy and integrate alerts into existing control room dashboards.

ACWA Power – Desalination Plant Optimization (Saudi Arabia)

Conducted data mining and preliminary analysis on DCS historian data to identify energy-saving opportunities across multiple RO desalination trains.
Built digital process models to simulate and optimize specific energy consumption (kWh/m³), presenting case studies with potential savings up to $407,000/year.
Prepared a techno-commercial proposal including solution architecture, implementation roadmap, and ROI analysis for plant-wide optimization.

Vedanta Alumina Smelter – Fuel & Cooling Water Optimization (Odisha, India)

Conducted preliminary energy assessment to identify optimization opportunities in fuel oil and cooling water consumption.
Analyzed DCS data trends and calculated specific energy consumption (SEC) to establish performance baselines.
Recommended optimized setpoints for air-to-hydrate and air-to-fuel ratios, achieving daily savings of $7,000 in fuel and $700 in cooling water.
Prepared a techno-commercial proposal detailing project scope, methodology, timeline, and cost-benefit analysis.

SWANCOR – Condenser Feasibility & Optimization (Taiwan)

Developed and refined digital twin models to investigate solvent loss issues in specialty chemical condensers.
Analyzed TEMA sheets, P&IDs, and control system data to identify root causes of operational inefficiencies.
Recommended optimized DCS setpoints that reduced vapor losses and improved condenser efficiency by 12–15%.
Collaborated with SWANCOR’s engineering team to validate model predictions and implement improvements.

ABG Hindalco – Alumina Calcination Fuel Optimization (Jharkhand, India)

Performed particle size distribution analysis and process modeling to optimize Specific Thermal Energy of Calcination (STEC) while maintaining product quality.
Developed custom DWSIM models using PFDs and DCS snapshots to identify optimal air-to-fuel and air-to-hydrate ratios.
Delivered a techno-commercial proposal with detailed engineering recommendations, expected outcomes, and cost-benefit analysis.

GODREJ – Distillation Column Retrofit Optimization (Maharashtra, India)

Created a digital twin of the FADP distillation column in DWSIM to diagnose throughput limitations and identify retrofit opportunities.
Conducted on-site visits to gather operator insights and validate simulation assumptions, leading to a 10–15% increase in feed rate with minimal energy penalty.
Deployed the optimized model on a cloud-based platform for real-time monitoring and scenario analysis.

TES-AMM – MVR Process Energy Optimization (Singapore)

Analyzed SCADA data trends to pinpoint energy waste during startup operations in a Mechanical Vapor Recompression system.
Built a detailed process model in DWSIM to simulate pumps, compressors, and heat exchangers, identifying key performance bottlenecks.
Translated Chinese P&IDs into English and extracted pump curves from vendor documents to enhance model accuracy.

Aleph Tech Stack – Product Development & Features

Contributed to the development of Aleph’s digital twin platform, designing backend calculation modules for mixers, columns, reactors, and separators.
Authored white papers on optimization of chillers, distillation columns, and gas-fired boilers using ALEPH CO-PILOT.
Developed a Python–DWSIM connector to enable batch simulation, automated data extraction, and parametric studies, reducing manual effort by 60%.

Carbon Emissions and Carbon Footprints Calculator | Team Size – 1 Member | Completed |

Currently working on Carbon Emissions and Carbon Footprints calculator for Singapore, to forecast the reduction of carbon emissions by reducing the demands today.
The basis of this project was taken as McKay-Carbon-Calculator and was modified according to Singapore needs and demands for Cambridge cares

CCGT (Combined Cycle Gas Turbine Power Plant) | Team Size – 2 Members | Completed |

Worked on a Combined Cycle Power Plant Simulation Case Study to optimize the steam flow to the turbines using the python connector.

AFZAR Consultants LLC

Process Engineer | Jan 2021 – Apr 2022

ADNOC Gas Processing – FEED & DED Engineering (Abu Dhabi, UAE)

Delivered 25+ updated FEED P&IDs and defined isolation, vent/drain, and ESD philosophies for the Habshan-3 NGI compressor conversion project.
Provided process support for instrumentation upgrades, revising 250+ P&IDs based on obsolescence reports and I/O lists for WOOD PLC.
Participated in alarm rationalization workshops for ADNOC offshore facilities (NGTP, UZ, GPF).

BSS Technologies – Electro-Chlorination Plant Design

Developed basic engineering package including PFDs, P&IDs, H&MB, line sizing, and equipment datasheets for seawater-based sodium hypochlorite generation.
Performed hydraulic calculations and supported 3D modeling in AutoCAD 2020.
Coordinated with vendors for pump curves and material specifications, ensuring design compliance with client requirements.

🛠️ Technical Skills

Process Engineering	Simulation & Digital Tools	Programming & Automation	Software & Platforms
PFD & P&ID Development	DWSIM (Advanced)	Python (Data Analysis, Automation)	Aspen HYSYS, PRO-II
Line Sizing & Hydraulics	Digital Twin Modelling	DWSim-Python Connector	HTRI, AFT Products
PSV Sizing (API 520)	Cloud Deployment of Models	Batch Simulation Scripts	AutoCAD, Bluebeam Revu
SIL Verification, C&E Diagrams	Static & Dynamic Simulation	Jupyter Notebooks	SMath Studio, Pipe-Net
HAZOP, Alarm Rationalization	Korf Hydraulics	Excel VBA, Macros	MS Office Suite
Process Safety Philosophies	PRO-II, HTRI Basics	Git Version Control	OneNote, SharePoint

📂 GitHub Portfolio & Projects

Process Simulation Repository – A collection of DWSIM models for distillation, reactors, heat exchangers, and energy systems used in client projects.
Process Automation Repository – Python-based tools for automating simulations, data extraction, and parametric studies using the DWSim-Python connector.
Python Practice Projects – Scripts for data analysis, visualization, equipment curve fitting, and workflow automation in process engineering contexts.

🏆 Key Achievements

✅ Developed Singapore-specific McKay Carbon Calculator for NUS and investor use in emission forecasting.
✅ Delivered 200+ P&IDs, 39 C&E diagrams, and 39 Process Control Narratives for ExxonMobil’s refinery ESD upgrade.
✅ Created and deployed a cloud-based digital twin for GODREJ’s FADP column, enabling real-time optimization.
✅ Won 2nd Prize in Gujarat Cleaner Production Centre competition for innovative waste management technology.
✅ Qualified CII Industrial Proficiency Test (2020) Topper in Polymer Technology, MSU Baroda.

🎓 Education

M.E. in Polymer Technology – Maharaja Sayajirao University, Baroda (First Class with Distinction, 70.1%)
B.E. in Chemical Engineering – Gujarat Technological University (CGPA: 8.86/10)
Higher Secondary Certificate – Baroda Public School (64.8%)
Secondary School Certificate – Shree Ambe Vidhyalaya (88.4%)

📬 Let’s Connect

📍 Address: B/17 Poonam Complex, Waghodia Road, Vadodara, Gujarat 390019
📩 Email: virajdesai0309@gmail.com
📱 Phone/WhatsApp: +91-8849093417
🔗 GitHub: github.com/virajdesai0309
🔗 LinkedIn: linkedin.com/in/viraj-desai-0309

Viraj Desai