Process Engineer - Chemical Simulation & Optimization

Akshay Meshiya

Process Engineer

856-***-**** ******.*********@*****.*** LinkedIn NJ, USA

PROFILE

Process Engineer with 4+ years of experience in chemical process simulation, plant optimization, and process safety across high-purity manufacturing and petrochemical environments. Delivered $2.5M+ in CAPEX projects and reduced unplanned downtime by 15% through real-time KPI monitoring and root cause analysis. Engineered process improvements achieving 10% throughput gains and 7.5% recovery improvements across batch and continuous operations. WORK EXPERIENCE

Process Engineer Apr 2026 - Present

Valcor Engineering Corporation NJ

● Engineered high-purity chemical processes using Aspen Plus, HYSYS, and ChemCAD, improving solvent recovery efficiency by 7% while maintaining stringent environmental compliance standards.

● Executed $2.5M+ in CAPEX projects by commissioning ultra-high-purity gas and liquid delivery systems and integrating with SAP PP/PM to strengthen maintenance visibility and equipment traceability.

● Reduced process variability across batch and continuous operations using SPC and downtime analytics, improving throughput and sustaining cleanroom-grade purity requirements.

● Developed PFDs, P&IDs, and 3D plant layouts in AutoCAD Plant 3D and SmartPlant P&ID, enabling 12 equipment upgrades that increased unit production capacity by 10%.

● Deployed OSIsoft PI System and Power BI dashboards to monitor critical KPIs and process trends in real time, accelerating fault detection and cutting unplanned downtime by 15%.

● Led HAZOP and LOPA studies alongside root cause investigations, identifying 10+ safety and operational risks and maintaining full audit readiness under tightly controlled regulatory frameworks. Process Engineer Jan 2023 – Jun 2024

R.R. Chemical India

● Built and validated 6 ChemCAD simulation models to optimize distillation and recovery processes, improving product recovery by 7.5% and reducing rework in downstream units.

● Investigated 20+ batch interruptions using Minitab, root cause analysis, and SPC methods, executing corrective actions that improved production continuity by 15% across critical batch operations.

● Automated sequencing triggers in OSIsoft PI System, minimizing manual operator interventions and reducing batch transition errors across 3 production shifts.

● Revised interlock logic and updated MSDS and EHS documentation for revamped process lines in collaboration with safety and compliance teams, ensuring audit readiness during active plant changes.

● Streamlined 250+ legacy SAP PM tasks, eliminating duplicate work orders and improving proactive maintenance scheduling, contributing to an 18% reduction in reactive job volume.

● Redesigned AutoCAD P&ID layouts around 4 high-traffic pump stations, increasing equipment accessibility and reducing technician field time by 20 minutes per shift.

Process Engineer May 2020 – Dec 2022

Palsana Enviro Protection Ltd India

● Constructed and maintained steady-state Aspen HYSYS models for olefins and propylene recovery units, supporting capacity debottlenecking that increased plant throughput by 10%.

● Analyzed 3 months of heat exchanger data using Python (Pandas, Matplotlib) to identify fouling trends early, extending cleaning intervals from 5-day to 30-day cycles and improving uptime by 8%.

● Automated KPI tracking across 5 continuous units via customized Excel dashboards, cutting daily reporting time by 35% and improving operational data accuracy.

● Implemented 5 full-scope HAZOP reviews and updated 20+ critical EHS documents during major feedstock and catalyst transitions across multiple process units.

● Coordinated a site-wide turnaround using Microsoft Project, ensuring safe execution and on-time completion with 300+ personnel across all disciplines.

● Optimized steam and reflux parameters across 3 distillation columns alongside process control teams, enhancing separation efficiency and achieving ~55 tons/month in steam savings.

● Trained 30+ engineers and field operators on startup sequences, loop logic, and troubleshooting workflows, reducing operational shift errors by 18%.

PROJECTS

Manufacturing of Ethylamine — B.E. Final Year Design Project

● Designed a conceptual 100 TPD Ethylamine production facility; performed material and energy balances, equipment sizing, cost estimation, and process safety evaluations.

Manufacturing of Ethylene Glycol — Diploma Final Year Design Project

● Executed process design, feasibility analysis, material balance calculations, utility assessments, and process economics evaluations.

SKILLS & OTHERS

Process Simulation & Design Aspen Plus, Aspen HYSYS, ChemCAD, AutoCAD P&ID, AutoCAD Plant 3D, SmartPlant P&ID, PFD/P&ID Development, Equipment Sizing, Heat & Mass Balances, Plant Layout Design Data Analytics & Visualization Python (Pandas, NumPy, Matplotlib), Power BI, Minitab, KPI Monitoring, Statistical Process Control (SPC), Control Charting, Process Diagnostics Plant Operations & Project Execution OSIsoft PI System, SAP (PP/PM Modules), Microsoft Project, Primavera (Basic), Turnaround Planning, CAPEX Project Management, Maintenance Coordination Process Safety & Compliance HAZOP, LOPA, PHAWorks, PHA Pro, SAP EHS, Risk Assessment, Safety Interlock Review, MSDS Handling, EHS Documentation

Productivity & Collaboration Microsoft Excel (Advanced), Cross-Functional Team Collaboration, Root Cause Analysis (RCA), 5 Whys, Downtime Analysis, Energy Balancing

EDUCATION

Master of Science, Chemical Engineering — Rowan University Aug 2024 – May 2026 Bachelor of Engineering, Chemical Engineering — Gujarat Technological University Jun 2018 – Apr 2021 Diploma, Chemical Engineering — Gujarat Technological University Jul 2015 – Mar 2018

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