Mayank Kashyap

About Mayank Kashyap

Ph.D. Chemical Engineer and technical leader with 15+ years of experience in reactor design, process development, scale-up, and optimization of gas-solid multiphase systems. I specialize in particle technology and fluidization (PT & F), translating complex multiphase phenomena into reliable, high-performing industrial reactor technologies. My work integrates fluidization science, multiphase CFD, cold-flow modeling (CFM), and experimental validation to bridge modeling, testing, and plant operations, enabling informed engineering decisions, reducing scale-up risk, and improving reactor performance, reliability, and safety. I have led the development and advancement of fluidized-bed and circulating fluidized-bed reactors (FBR/CFBR) across laboratory-to-commercial scales, bringing technologies from concept through commercial readiness. I have delivered $170MM+ per year in business impact through reactor troubleshooting, performance improvement, and process enhancements across global petrochemical and polymer assets. Selected contributions include:· Naphtha Catalytic Cracking (NCC): Led scale-up of a novel CFBR technology to Gate 5 using pilot testing, CFM, and model-informed design (DICP, PSRI).· Chemical Looping ODH (CL-ODH): Co-PI on a U.S. DOE-funded program for decarbonized ethylene; engineered CFBR systems addressing multiphase hydrodynamics and redox kinetics while supporting techno-economic and life-cycle analyses (TEA/LCA).· SYNOVA MILENA (Mixed Plastic Waste (MPW)-to-Olefins): Led scale-up strategy and risk-retirement via piloting (TNO) and large-scale CFM (PSRI).· Multiphase CFD Capability Development: Established CFD capability to guide reactor design and enable scale-up across lab, pilot, and industrial systems.· Industrial Reactor Optimization: Resolved fluidization-driven limitations across global polyolefin and dehydrogenation units, improving yield, reliability, and safety, delivering >$160MM/year value. I am particularly passionate about advancing technologies in the circular economy, decarbonization, and petrochemical innovation, where robust reactor design and effective scale-up are critical to success. I have led cross-functional programs and industry collaborations, directing $4MM+ in R&D investments across academia, consortia (PSRI), and technology partners. Inventor on 12 patent families (35+ filings); author of publications and a book; recipient of multiple awards including the AIChE George Klinzing Best Ph.D. Award.

Experience

1. Staff Scientist - Advanced Modeling, Specialized Competencies, Technology Platform, Chemicals t & i

   SABIC

   Apr 2025 — Present · Houston, TX, US

   Global technical leader in process technology development, reactor scale-up, and plant support across chemicals and polymers portfolios, leveraging deep expertise in PT & F. • Business Impact & Operational Excellenceo Delivered >$163MM/year in business value, including 70% catalyst loss reduction and 22% capacity increase on a flagship unit.o Provided expert troubleshooting support to isobutane dehydrogenation, polypropylene, and polyethylene assets, improving yield, reliability, safety, and product portfolio. o Led implementation of planned and field-driven improvements during plant turnarounds and commercial trials, translating R&D insights into measurable performance gains.o Expanded modeling into polymer processing by developing SABIC’s first TSE modeling capability.• Technology Development & Reactor Scale-Up o Steered circulating fluidized-bed reactor (CFBR) development and scale-up for NCC, leading Dalian Institute of Chemical Physics (DICP) and PSRI collaborations to achieve Gate 5 readiness.o Enabled critical scale-up decisions and reduced risk through pilot trials at DICP and The Netherlands Organization for Applied Scientific Research (TNO) and large-scale CFM programs at PSRI.o Guided industrial fluidized-bed reactor (FBR) design, scale-up, and process optimization, improving performance and operational safety through advanced CFD modeling (e.g, Barracuda Virtual Reactor® (BVR®)) validated with experimental and plant data.o Led catalyst attrition testing and scale-up studies to ensure FBR durability and performance.

Education

• Illinois Institute of Technology

  Doctor of Philosophy (Ph.D.), Chemical Engineering

  2004 — 2010

• Panjab University

  Bachelor of Engineering (B.E.), Chemical Engineering

  2000 — 2004

Skills

• Simulations
• Fluid Dynamics
• Solids Handling
• Mass Transfer
• Thermodynamics
• Cfd
• Fluidized Bed Reactor Design
• Process Simulation
• Process Engineering
• Research and Development (R&D)
• Heat Transfer
• Ansys
• R&D
• Experimentation
• Design of Experiments
• Multiphase Flow
• Reaction Engineering
• Particle Engineering
• Piv
• Engineering
• Chemical Engineering
• Fluidization
• Modeling