GANESH S. THORAT

• Project Accomplishments: Successfully completed and commissioned a 160 Cr. Multipurpose plant, delivering results on schedule and to desired specification.
• Process Scale-Up: Expertly scaled up three new molecules, achieving a seamless 1000-fold increase from the kilo lab, with successful delivery of 4000 kg batch sizes.
• Yield Improvement: Enhanced flagship product yield from 73% to 83%, driving significant value in production efficiency and cost savings.
• Team Leadership: Currently lead a dedicated team of 3 chemical engineers, including an Assistant Manager and two Executives, fostering a collaborative environment to achieve department as well as organization goals.

Project Highlights:

• Completed a major capacity enhancement project for Al(OH)3 production, increasing throughput from 4.0 TPM to 20 TPM from waste stream.
• Prepared Capex for a backward integration project with a 242 TPM capacity, securing a project budget of 104 Cr.
• Completed 12 Cr. Capacity enhancement project of premium product, increasing production from 36 TPM to 50 TPM.

Achievements:

• Successfully scaled up lab batches to pilot plant and plant scale for two products, leading to their commercialization.

Ongoing Projects:

• Currently leading a 12 Cr. Capacity enhancement project for PY-110, increasing production from 36 TPM to 50 TPM.

Leadership:

• Led a team of 2 members, focused on achieving strategic process and capacity targets.

Completed Capacity enhancement Project from 30 TPM to 40 TPM plant of QA Plant.

• Achieved significant time cycle reduction in filtration activity boosting plant productivity from 75 TPM to 80 TPM, and Distillation column capacity increased from 8 KLD to 17 KLD.
• Led a water recycling initiative, saving 200 KLD, supporting sustainability, and operational efficiency.

Core Responsibilities:

• Developed conceptual plant layouts, project plans, and scheduling using bar charts for existing and new products.
• Managed troubleshooting, debottlenecking, and capacity planning of existing products to improve productivity.
• Involved in the product costing and utility costing of new and existing molecules.
• Prepared Capex for greenfield and brownfield projects.

Achievements:

• Developed budgetary costing and Capex for multiple projects, prepared BEP, PFDs, P&IDs, and conceptual layouts to support project planning.
• Successfully erected and commissioned a 6-unit hydrogenation plant and a multipurpose plant with 24 reactors, 48 condensers, 5 ANFDs, 10 storage tanks, and 3 centrifuges.
• Enhanced MEE plant capacity from 90 KLD to 200 KLD through strategic modifications.
• Completed timely erection and commissioning of an ATFD (30 m²) and a 12 TPH boiler.

Core Responsibilities:

• Lead project detailing, including PFD, P&ID, layout, and UFD preparation.
• Develop detailed work bar charts, project schedules, and manage procurement processes.
• Coordinate with vendors, consultants, and manufacturing units, oversee vendor drawing reviews, and ensure timely project execution.

Key Responsibilities:

• Reviewed vendor documents and provided technical coordination to resolve queries from vendors and clients.
• Prepared detailed engineering documents, including PFD/E&M, P&ID, and UFD, for essential systems like boilers, cooling towers, chilled water, DM water plants, and fire water systems.
• Created process datasheets for pumps and storage tanks, as well as IPDS and equipment specifications, ensuring compliance with client and project standards.

Production (50 MT/month)

• Key Responsibilities: Developed PFDs, line lists, and calculated Bills of Material based on piping layouts, ensuring project readiness.
  Conducted hydraulic calculations, selected appropriate pipe sizes, pumps, and prepared specification sheets.
  Designed essential heat exchangers and scrubbers for handling HBr gas, HCl, and HBr.
  Coordinated across multiple departments (Civil, Piping, Instrumentation, and Electrical) to ensure seamless integration.
  Scheduled and managed project timelines, executed process calculations for tank and line sizing, oversaw unit erection, and ensured smooth commissioning and troubleshooting.
  Scaled up equipment from pilot plant to commercial scale, achieving optimal production levels.
  

Core Responsibilities:

• Lead production planning activities, overseeing batch operations for equipment such as reactors, ANFD, and centrifuges.
• Managed handling and safe storage of chemicals, including Toluene, Acetone, Methanol, TiCl4, and Hexane.
• Directed housekeeping efforts to maintain plant standards and efficiency.
• Prepared daily stock reports for raw materials (RM) and finished materials (FM), supporting inventory accuracy and resource planning.
• Actively participated in safety initiatives to uphold plant safety and regulatory compliance.

Core Responsibilities:

• Analyzed, developed, implemented, and maintained efficient manufacturing operations to enhance production outcomes.
• Led production planning initiatives, ensuring optimal resource allocation and output.
• Hands-on experience managing distillation column operations, with in-depth knowledge of separation processes.
• Operated and optimized an 80 MT/day continuous Ethyl Acetate plant, focusing on stability, quality, and efficiency.