Experience as Process Engineer

• Employer

  Fatima Fertilizer Company Limited

• From

  17 June 2019

• To

  To date

• Detail

  · Daily monitoring of phosphate production facility and troubleshooting of chronic issues to ensure stable operations through strict compliance of SOP’s and reinforcement of personnel.
  · Techno-commercial feasibilities of revamps, new projects, and debottlenecks for capacity uprate.
  · Prepared engineering packages under MOC protocol.
  · Preparation of technical reports exhibiting process equipment performance.
  · Participated in safety studies, process hazard analysis (HAZOP) of the major new facility as a member, and pre-startup safety review (PSSR).
  · Independently lead a team comprising 10 operators for the replacement of absorption tower packing safely. Coordinated with supply chain, maintenance, and warehouse for a successful installation.
  · Performance evaluation/rating of critical heat exchangers and control valves and pumps.
  · Revamped process-related documents; process safety information (PSI) packages as per process safety management (PSM) guidelines
  · Commissioning of new process equipment, creating data sheets/PFD/P&IDs and sops for its operation.
  · Support the development of capital projects and/or product diversification opportunities relevant to Nitrates & Phosphates that will enable the Group to achieve its long-term vision.
  · Contribute to the identification of opportunities for continuous improvement of processes and practices taking into account ‘international best practice’, improvement of business processes, cost reduction, and productivity improvement.
  · Evaluate business cases/costing during pre-feasibility studies for major/non-major projects. This also includes managing third parties to conduct engineering and business studies and interaction with counterparts within Shareholder companies for selected projects.
  · Conducted ISO 9001/14001 and 45001 audits of the process engineering department
  · Development of rock phosphate beneficiation plant to remove impurities and enhance phosphorus content
  
  PRILL TOWER FAN MODIFICATIONS FOR PLANT CAPACITY UPRATE
  · Prill tower fan pitch angle changed for increased airflow in tower accounting for 15-20oC decreased temperature/ 30 MTPD production gain.
  PLANT EQUIPMENT BENCHMARKING
  · Comparison of falling film evaporators (FFE) of several industries to benchmark best practices and prepare improvement plans to prevent production loss.
  · Bench-marking and troubleshooting acidic scrubbers to meet emission standards.
  HUNTING AND EVALUATION OF ALTERNATE SOURCES OF RAW MATERIALS
  · Cost optimization study and implementation of worldwide Rock Phosphate reserves as a source of P2O5 for phosphate fertilizers leading to saving 250 MN. PKR/year