Engr. Faizan Ali

Chemical Engineer with hands-on experience in continuous process industries including petrochemical and ethanol production plants. Skilled in DCS-based operations (Honeywell), process monitoring, troubleshooting, and safe plant operations. Experienced in sulphonation, distillation, utilities management, and energy optimization with a strong focus on HSE compliance and operational reliability. Seeking to contribute to large-scale oil & gas operations.

Production Engineer – Process at Tufail MultiChem Industries (2025-09 – Present)

• Leading shift operations of 144 TPD LABSA & SLES manufacturing plant based on Weixian technology.
• Responsible for safe and efficient operation of complete sulfonation and ethoxylation downstream processes including LABSA and SLES production.
• Supervise complete sulfur burning and SO₂/SO₃ conversion system including air drying unit, sulfur furnace, multi-bed converter, gas coolers, mist filtration, and SO₃ reactor.
• Manage production of LABSA and SLES (1 Mole, 2 Mole, 3 Mole) by controlling feed ratios, reaction parameters, and downstream neutralization processes.
• Supervise stripper vacuum system for dioxane removal and final product quality compliance.
• Oversee dosing and process control of caustic, water, buffer solution, and Hydrogen peroxide in SLES finishing section.
• Manage Waste Heat Recovery Unit (WHRU) for steam generation through recovered process heat, contributing to plant energy efficiency and utility cost reduction.
• Lead shift team, coordinate with maintenance, utility, lab, and production departments for smooth plant operations.
• Handle plant startup, shutdown, troubleshooting, emergency response, and process deviations.
• Prepare production reports, shift logs, incident reports, and operational documentation.
• Ensure compliance with process safety, quality standards, and environmental requirements.

Assistant Shift Engineer at Unicol Limited (2024-10 – 2025-09)

• Operated distillation processes through Honeywell DCS to produce 96.5% ethanol.
• Managed Molecular Sieve Dehydration (MSDH) system for production of 99.96% anhydrous ethanol.
• Oversaw biogas generation, boiler operations, CO₂ recovery, and energy optimization systems.
• Monitored process parameters and ensured smooth plant operation with minimal downtime.
• Performed routine field inspections and coordinated with maintenance teams for efficient operations.

Bachelor of Engineering in Chemical – Mehran University Of Engineering & Technology (2020 – 2024)