Overview
Work History
Education
Skills
Websites
Software
Accomplishments
Research Highlights
Project Highlights
Important coursework
Timeline
Generic
Akhil Sukumaran Nair

Akhil Sukumaran Nair

New York,NY

Overview

8
8
years of professional experience

Work History

Advanced Process Controls and Optimization Engineer

Corning Incorporated
01.2023 - Current
  • Enhanced the MCS proprietary MATLAB-based QDMC class for Non linear Model Predictive control by adding band gap control and soft constraint capabilities. Developed the class as a Python package and steered its migration to increase interoperability and reduce reliance on closed source software.
  • Successfully deployed and configured control systems, tuned parameters for optimal performance based on multi-objective optimization techniques and maintained the integrity of PLC & HMI software interface across China, India, Italy and North America.
  • Led integration of image recognition and unsupervised learning based process monitoring into Corning's predictive maintenance strategy. Established relevant KPIs to track performance and developed web applications to enhance business verticals operational efficiency.
  • Delivered on initiatives to optimize capital manufacturing processes by working on enabling low-latency data ingestion, development of python based CI/CD pipelines for data , implementing data cleaning, version control, hypothesis testing, code reviews and A/B testing mitigating data pipeline bugs.

Assistant Manager - Data Analytics and Control

Bharat Petroleum Corporation Ltd
01.2019 - 08.2021
  • Analyzed crude oil behavior using LSTMs to optimize product dispatch and maximize refinery gross refining margin alongwith BCG. Created a database of BPCL's product basket based on crudes purchased from 9 leading OPEC nations with changing refinery configurations. (GRM improvement: 100K USD+ pm)
  • Deployed Model based controls strategies across Refinery Heaters, Hydrogen networks,Sulphur recovery systems and Wet gas compressors using Aspen DMC-3 and actively supported the Advanced Process controls portfolio (Projected savings of 42K USD+ pm)
  • Led refinery scheduling and planning using Aspen PIMS for meeting customer demand & optimization based on time series forecasting.
  • External Energy Auditor to Reliance, MRPL and HMEL Bhatinda -India as a part of EnMS (GoI) - BPCL Young Energy Award.

Manufacturing Process Engineer - Refinery

Bharat Petroleum Corporation Ltd
01.2017 - 01.2019
  • Developed Aspen-HYSYS based steady state simulation for the DCU/PFCCU refinery units and troubleshooted daily performance issues.
  • Drove Fluent based CFD studies to estimate Coke drum stresses, Heater efficiency and WGC surge test to reduce surge margin.
  • Involved in design and FEED of filtration systems, energy recovery units , Flare systems, steam networks and sizing equipments during retrofits.
  • Identified as the BPCL Process Safety Management champion for DCU- Compliance auditor, PSI, PHA, MOC, IRIS, EP-TPA
  • Led a group of 125 operators in BPCL KR - IREP commissioning & PFCC-DCU Turnaround to ensure timely project completion
  • Active monitoring of DCU, PFCCU and CDU plants from control room using DCS liaising with Yokogawa, Honeywell, Schneider and Emerson systems.

Education

Master of Science (MS-AI) in Chemical Engineering -

Carnegie Mellon University
Pittsburgh, PA
12.2022

Bachelor of Technology in Chemical Engineering - undefined

Government Engineering College -Thrissur
Thrissur, Kerala
05.2017

Skills

  • Python
  • MATLAB
  • C
  • SQL
  • Py-CUDA

Software

Aspen PIMS, DMC-3, GDOT

GAMS, Julia, AMPL

Solvers: IPOPT, CPLEX, GUROBI, OSQP, FMINCON

Python - PYOMO , OMLT, PuLP , CVXOPT

Accomplishments

  • Numpy, Pandas, Polars
  • Scikit Learn, PyTorch
  • Matplotlib, Selenium
  • PowerBI, Tableau
  • PowerShell
  • GitHub, GitLab
  • AWS - EC2, Lambda

Research Highlights

  • Superstructure optimization of circular plastics value chain - Flexibility Analysis (Asian PSE-22, AICHE -23)

(Modeled a cradle-2-gate circular PET plastic superstructure, based on data driven, ML-based surrogates and solved the resulting MO-MILP problem, under epistemic uncertainty to identify optimal frameworks for the PET supply value chain)

Project Highlights

  • MPC performance monitoring algorithm development and dashboarding (Corning) : Developed an algorithm within the QDMC class using MATLAB to benchmark control model performance and trigger system re Identification for 120+ MPC applications across Asia and US. Deployed real time Grafana dashboards. (16 priorities identified)
  • Bi-level Real Time Optimization (RTO) for equipment life enhancement (Corning): Composed a weighted RTO problem to find oxidation compensated temperature SP to feed into lower level MPC loop. Used a CFD inspired PINN model to solve a secondary RTO problem to maintain product quality while avoiding thermal hotspots on the equipment.
  • Advanced controls framework for highly nonlinear unit start-up (Corning) : Used an adaptive gain based PID control to replace bang-bang controls and tuned it. Conducted comparison studies between First principles, Mass balance and LSTM based data models to capture model physics and develop a hybrid NMPC controller. (Reduced 2.5% of overall product breakage)
  • Rigorous MINLP model for Power (CPP) distributions (CMU) : Ideated a technique to penalize emissions & award carbon credits of operating equipment by revising IBM's Rigorous distillation model using STEAM and created a pareto front for weights optimization. Benchmarked BARON, DICOPT solvers for non linear initialization & finding global optima.
  • Increasing efficiency of Transhipment Network models for fleet optimization : Tested efficiency of an Edmond Karp algorithm based formulation against a self-tuned GSA based metaheuristic. (Reduced 2% of median solution time)
  • Predicting the Time to coke & Shutdown of Fouling Industrial Heaters (CMU) : Benchmarked shallow & deep ML algorithms in Python for designing coke accumulation on heater tubes, deployed efficient PCA basis to represent 94% information by 5:1 compression, devised PINN's and LSTM RNN models Test accuracy of 93.1%

Important coursework

  • Chemical Reaction Engineering
  • Machine Learning
  • Modern Convex Optimization
  • Multi Criterion Decision Making
  • Quantum Integer Programming
  • Intermediate Deep Learning
  • Process Dynamics & Control
  • Non-Linear Programming

Timeline

Advanced Process Controls and Optimization Engineer

Corning Incorporated
01.2023 - Current

Assistant Manager - Data Analytics and Control

Bharat Petroleum Corporation Ltd
01.2019 - 08.2021

Manufacturing Process Engineer - Refinery

Bharat Petroleum Corporation Ltd
01.2017 - 01.2019

Master of Science (MS-AI) in Chemical Engineering -

Carnegie Mellon University

Bachelor of Technology in Chemical Engineering - undefined

Government Engineering College -Thrissur
Akhil Sukumaran Nair