Mayank Kashyap
Staff Scientist - Advanced Modeling, Specialized Competencies, Technology Platform, Chemicals t & i @SABIC
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WORK HISTORY
Staff Scientist - Advanced Modeling, Specialized Competencies, Technology Platform, Chemicals t & i @SABIC
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
Panjab University
Bachelor of Engineering (B.E.), Chemical Engineering
SKILLS
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.
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