Sayani Thakur
Jamnagar
Summary
Results-driven professional with 10+ years of experience in catalytic process development, reactor and kinetic modeling, and scale-up. Proven success in multi-catalytic cracking, waste plastic conversion, catalytic gasification, and alkane dehydrogenation. Adept at experimental research, mathematical modeling, and cross-functional collaboration to deliver high-value outcomes. Passionate about developing sustainable, cost-effective technologies that drive circular economy, improve energy efficiency, and produce green fuels and chemicals.
Overview
12
12
years of professional experience
Work History
SENIOR RESEARCH SCIENTIST, REFINING R&D
RELIANCE INDUSTRIES LIMITED
Jamnagar
01.2025 - Current
- Company Overview: Catalytic Gasification of Biomass to Hydrogen
- Developed a sustainable, low-temperature gasification technology for green H₂ production from biomass
- Developed a sustainable, low-temperature gasification technology for green H₂ production from biomass
- Executed fixed-bed and fluidized-bed reactor experiments for multiple feedstocks; optimized conversion and H₂ yield
- Created kinetic and pilot reactor models to identify kinetic parameters and perform sensitivity analyses; utilized 1D model for 1500 TPD plant BDEP
- Achieved green H₂ cost of $1.6/kg and estimated potential EBITDA of $1500 MM (from 50 MT biomass/day)
- Published external paper in Energy & Fuels (2019, 33, 2453–2466)
- Co-invented a cost-effective chemical recycling solution for waste plastics to pyrolysis oil; advanced the process from TRL 1 to TRL 9
- Designed and executed 400+ lab-scale (10 gm) and 50+ pilot-scale (10 kg) experiments over three years, generating a comprehensive data bank
- Collaborated with waste management vendors to optimize feed logistics and demonstrated the in-house technology in a 2 TPD demo unit
- Developed unsteady-state kinetic model (MATLAB) and rotary kiln hydrodynamic model to scale up from 2 TPD to 25 TPD
- Performed product characterization for co-processing in Coker, FCC and cracker and validated feasibility for 500 KTPA co-processing
- Secured US Patent (US 11 319 493) and submitted BDEP for four 25 TPD modular plants, with potential to set up 350 plants across India
- Competitive advantage of in-house pyrolysis oil: ~$100/bbl
- Leading catalytic non-oxidative dehydrogenation for C2/C3 feed in a fluidized-bed reactor
- Driving Cr-based catalyst development (+10% higher conversion, +5% selectivity, low deactivation)
- Executing lab experiments for catalyst performance evaluation; integrated deactivation kinetics and Kunii-Levenspiel (K-L) model for reactor design
- Catalytic Gasification of Biomass to Hydrogen
- Developed a sustainable, low-temperature gasification technology for green H₂ production from biomass
- High business value vs
- Competitive technologies
- Substantially high business value as compared to competitive technology
RESEARCH SCIENTIST, REFINING R&D
RELIANCE INDUSTRIES LIMITED
Jamnagar
06.2017 - 10.2021
- Company Overview: Kinetic Model Development for Multi-zone catalytic process (MCC)
- Developed 1D steady-state, 17-lump kinetic and hydrodynamic model in C++/MATLAB for novel MCC technology
- Developed 1D steady-state, 17-lump kinetic and hydrodynamic model in C++/MATLAB for novel MCC technology
- Validated model with 100+ experimental data points and achieved R² > 0.9 vs
- Commercial FCC plant data
- Findings integrated into Process Design Package (PDP), facilitating successful demonstration and commercialization
- Innovated processes for catalytic conversion of woody/non-woody biomass to high-quality bio-oil
- Conducted lab- and pilot-scale testing; developed kinetic models for torrefaction/pyrolysis to design 10 TPD torrefaction and 5 TPD pyrolysis plants
- Created non-linear regression model to analyze viscosity of gasifier slag/slurry
- Identified root causes of frequent shutdowns in the world’s largest pet-coke gasifier, recommending DCS implementation
- Kinetic Model Development for Multi-zone catalytic process (MCC)
- Developed 1D steady-state, 17-lump kinetic and hydrodynamic model in C++/MATLAB for novel MCC technology
- Potential benefit: $10 Mn savings annually
- Mentored 5 junior team members in fixed bed, fluid bed & rotary kiln experiments
- Managed inventory for lab consumables and spares
RESEARCH ASSISTANT
INDIAN INSTITUTE OF TECHNOLOGY
Mumbai
01.2015 - 01.2017
- Company Overview: Collaborated under Prof
- Devang Khakhar and Dr
- Rahna Hakim (DRDO)
- Commissioned cast-melt extrusion and corona-poling pilot plants; optimized process parameters for thin PVDF sheets
- Compiled findings in a technical report for IIT-Bombay and DRDO
- Prepared liposome suspensions (micro to nano range) and studied ethanol–lipid interactions
- Characterized vesicles with DLS, NMR, Viscometry
- Collaborated under Prof
- Devang Khakhar and Dr
- Rahna Hakim (DRDO)
PROCESS ENGINEER
PACIFIC & SCIENTIFIC CONSULTANCY PVT LTD.
Kolkata
01.2014 - 01.2015
- Company Overview: Oversaw project schedules from commissioning to steady-state operations
- Sized engineering equipment for air pollution control systems; developed budget estimates and project scopes
- Oversaw project schedules from commissioning to steady-state operations
Education
PhD - Chemical Engineering
INDIAN INSTITUTE OF TECHNOLOGY
BOMBAY, INDIA07-2025
B.Tech - Chemical Engineering
HERITAGE INSTITUTE OF TECHNOLOGY
Kolkata, India01.2014
Skills
- Mathematical Modeling
- MATLAB/C/Python
- Statistical Analysis
- Kinetic & Hydrodynamic Modeling
- Experimental Research
- Process Optimization & Scale-up
- Reactor Design
- Technical Writing
- Team Collaboration
- Project Leadership & Mentoring
Social Volunteering
Taught 20 underprivileged students of class V – X for maths and history, IIT’s program “Abhiyasika”, 2016
Awards Recognition
- R-Samman and Top Performance Ratings (A
- Top 5%), Reliance Industries, 2019–2025
- Nominated for R-ADHYA ‘Women Professional Lab – Batch 5’, Reliance Industries
- Best Poster Award, SCHEMCON 2012, BITS Pilani
- 1st Position in Inter-College Debate Competition, 2014, Eastern India
Publications
- A Method for Catalytic Conversion of Waste Plastic in to Liquid Fuel, Patent, S Daggupati, S Thakur, S Mandal, A Das, A V Spare, PCT/IB2019/057228
- 2-D model for Catalytic Pyrolysis of Waste Plastics in Rotary Kiln Reactor, Internal Report, S Thakur, S Das Sharma, A K Das
- Experimental data on conversion of polyolefin into liquid fuels, Internal Report, S Thakur, S Majhi, S Daggupati
- Techno economic options for converting waste plastics into liquid fuels, Internal Report, S Thakur, S Majhi, S Daggupati
- Catalytic conversion of Waste Plastic to Olefins/ Lighters Products/ BTX -A Review, Internal Report, S Majhi, S Thakur, S Daggupati
- Catalytic Gasification of Biomass in Dual-Bed Gasifier for producing Tar Free Syngas, Publication, S Mandal, S Daggupati, S Majhi, S Thakur, R Bandyopadhyay, A K Das, Energy Fuels 2019, 33, 2453−2466
- Scale-Up Studies on Catalytic Gasification Technology at University of Utah, Internal Report, S Daggupati, S Thakur, S Mandal, A Das
References
- Dr Asit DAS, HOD, Refining R&D, Reliance Industries Limited, Asit.das@ril.com
- Dr Sanjib DAS Sharma, Science Specialist, Saudi Aramco, Dhahran, Saudi Arabia, sanjib.dassharma@aramco.com
Hobbies and Interests
Dance, Trained 14+ years in Bharatnatyam & 3+ years Kathak dancer. Performed in several group presentations and also as a solo.
Conference Presentations
- Circular Economy—Sustainable Catalytic Conversion of Waste Plastic to a Stable Oil, 24th RPTM, 01/01/20, Bangalore
- Waste Plastics Conversion to Transportation Fuels, Annual Day, Reliance Industries, 01/01/20
- Performance Evaluation of Sewage Treatment Plant at Kolkata Metropolitan Area, 66th Annual Indian Chemical Engineering Congress (CHEMCON 2013), 01/01/13, ICT Mumbai
Activities
- Secretary, Indian Institute of Chemical Engineers, Hosted multiple seminars, workshops aligned with industry for 200 chemical engineering students along with inter-college technical quiz and debate on emerging technologies and green energy. Acquired industrial sponsorship of $0.02 Mn year-on-year in 3rd & 4th year of engineering.
- Host/Anchor, Heritage Institute of Technology, Annual Cultural Fest and every academic and cultural program organized by the Institute.
Timeline
SENIOR RESEARCH SCIENTIST, REFINING R&D
RELIANCE INDUSTRIES LIMITED
01.2025 - Current
RESEARCH SCIENTIST, REFINING R&D
RELIANCE INDUSTRIES LIMITED
06.2017 - 10.2021
RESEARCH ASSISTANT
INDIAN INSTITUTE OF TECHNOLOGY
01.2015 - 01.2017
PROCESS ENGINEER
PACIFIC & SCIENTIFIC CONSULTANCY PVT LTD.
01.2014 - 01.2015
PhD - Chemical Engineering
INDIAN INSTITUTE OF TECHNOLOGY
B.Tech - Chemical Engineering
HERITAGE INSTITUTE OF TECHNOLOGY