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Chetan Kotak B. Tech. (Chemical Engineering) (1985)

Work Experience Summary

31 years of experience in Process Simulation Modeling and its applications in Refineries, Petrochemical & chemical manufacturing Industries and Design & Engineering Industries

Process Simulation Modeling

  • Steady State using Aspen HYSYS (including SulSim), ASPEN PLUS, PRO/II, Petro SIM, ProTreat
  • Dynamic using Aspen HYSYS
  • Mathematical modelling and software development

Application of Process Simulation

  • In Process Plant Operating Industry
    • Optimizing Feed Selection, Feed blending, Operating Parameters, Product blending
    • Troubleshooting
    • Developing Operator Training Simulator (OTS)
  • In Process Plant Design and Engineering Industry
    • Development of Process Flow Diagram (PFD), Optimum Basic Design, Optimum Equipment Sizing
    • Special studies: Pressure Excursion, Temperature Transient, Checking Control Strategies, Sensitivity study

Professional Experience:

Integrated Steady State Process Simulation Modeling

Crude Distillation Unit, Vacuum Distillation Unit and Saturated Gas Unit (CDU, VDU and SGU)
Continuous Catalytic Reformer (CCR)
Fluidized Catalytic Cracker (FCC)
Diesel Hydro De-sulfurization (DHDS)
Coker & Gas Plant
Light Cycle Oil (LCO) Hydrocracker
Hydrogen Generation Unit (HGU)
Sulphur Recovery unit (SRU)
Sour Water Stripping System (SWS)
Ethylene plant
Enhanced Binary Refrigeration (EBR)
Butadiene Extraction Unit (BEU)
Ammonia plant including Reforming Exchanger System (RES) and Purifier Feed Effluent Exchanger
Carbon monoxide plant
Cryogenic Air Separation plant
Iso Propyl Alcohol (IPA) plant
iso-Butyl acetate / n-Butyl acetate – Acetic acid – Water Distillation Column
iso-Butyl Acetate, Acetic acid, Xylene, Water Distillation Column
Membrane separation process to separate Carbon monoxide & Hydrogen from their mixture
Thermal design, rating and simulation of shell & tube heat exchangers (about 100 count)

Integrated Dynamic Process Simulation Modeling


Gas Sweetening Unit (GSU)
Liquefied Natural Gas (LNG) unloading and Liquefied Natural Gas (LNG) re-gasification facility
Coal fired Thermal Power plant

Refineries, Petrochemical and Chemical Process Industries

To Process Plant Operating Companies

Development of Process Flow Diagram (PFD) and carrying out Optimum Basic design of Sour Water Stripping System (SWS) for removing Hydrogen Sulfide (H2S) and Ammonia (NH3 ) in different column
Development of Process Flow Diagram (PFD), Carrying out Optimum Basic Design and Optimum Equipment Sizing for System separating Methyl acetate(MA) and iso - Butyl acetate (IBA)
Basic Design of Crude Distillation Unit (CDU)
Remote Plant performance monitoring and providing Optimum Proces Plant Parameters to operating plant personnel of Crude Distillation Unit (CDU), Vacuum Distillation Unit (VDU), Saturated Gas Unit (SGU) with change in feeds and their blend
Remote Plant performance monitoring and providing Optimum Process Plant Parameters to operating plant personnel of Continuous Catalytic Reformer (CCR) with change in feed
Remote Plant performance monitoring and Provided Optimum Process Plant Operating parameters to plant operating personnel of Butadiene Extraction Unit (BEU).
Remote Plant performance monitoring and Providing Optimum Process Plant Operating parameters to plant operating personnel of Ethylene plant
Carrying out optimum feeds selection for processing them in Butadiene Extraction Unit (BEU)
Troubleshooting in Crude Distillation Unit (CDU). Troubleshooting Problem of High Final Boiling Point (FBP) of Stabilized Naphtha and Low Flash Point of Light Kero (LK)
Predicting fouling factors of reboilers in Butadiene Extraction Unit (BEU)
Design case and Actual case validation and Check for Target case for Diesel Hydro De-sulfurization (DHDS), Coker & Gas Plant, Light Cycle Oil (LCO) Hydrocracker
Process and production management in the Glass Wool plant. Improved quality to export standards, reduced fuel consumption by 20%, reduced scrap and downtime and increased throughput.
Saved US$150,000 by Executing task retaining the old crown of glass melting furnace in its re-build (the first time in company history)

To Design and Engineering Companies

Studying pressure excursion in Natural Gas (NG) send out header during emergency shutdown of Liquefied Natural Gas (LNG) Re-Gasification Facility
Adequacy check of flare header and Knock Out drum sizes and checking process control strategies for Liquefied Natural Gas (LNG) unloading station
Studying temperature transient in vapor return line during Liquefied Natural Gas (LNG) unloading
Studying sensitivity of operating parameters on separation of Hydrogen and carbon monoxide in membrane separation system
Thermal design, check-rating and simulation of shell & tube heat exchangers (about 100 count)

To IT Companies

Project planning, coordinating, and resource & work allocation for multiple development projects of PRO/II
Project planning, coordinating, and resource & work allocation for multiple customization projects of Plant Design System (PDS)
Developing Operator Training Simulator (OTS) of Gas Sweetening Unit (GSU) and Coal Fired Thermal Power Plant

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