AYOUB ALKHAAL

CITGO Biodiesel Terminal Expansion – Brownfield Capacity Upgrade

• Led front-end and detailed process design for a brownfield biodiesel terminal expansion, delivering a 25% increase in storage and shipping capacity and enabling revenue growth.
• Directed hydraulic debottlenecking study using AFT Fathom, identifying system constraints and justifying installation of a new storage tank and high-capacity centrifugal pump—avoiding costly pipeline replacement
• Developed comprehensive Process Design Basis and Hydraulic Study Report, securing client approval and accelerating project sanction
• Performed pump sizing (head, NPSH, system curve validation) and prepared equipment datasheets/RFQs, optimizing capital spend and lifecycle reliability
• Coordinated multi-discipline execution (civil, piping, instrumentation, safety), ensuring full compliance with OSHA, EPA, NFPA, and local codes while maintaining schedule and budget targets

Aromatic Recovery Unit (ARU) Maximize Distillate Optimization Project

• Led ARU optimization initiative with a group of process engineers increasing distillate recovery by ~5%, generating $750K/ year in incremental revenue.
• Performed material & energy balance analysis to identify and reduce off-gas and bottoms hydrocarbon losses
• Optimized reflux ratio, reboiler duty, column pressure, and solvent circulation to improve separation efficiency
• Utilized Aspen HYSYS simulation and APC tuning to define optimal operating window and reduce process variability
• Improved energy efficiency by ~6% while maintaining product specifications and safe operating margins

SRU Revamp Project

• Led detailed process design and optimization for a major SRU revamp, increasing sulfur recovery efficiency from existing units by ~12%, improving environmental compliance and reducing operational emissions.
• Conducted steady-state and transient simulations in Aspen HYSYSto validate SRU performance under varied operating scenarios, enabling more accurate design margins and supporting risk mitigation.
• Developed critical process deliverables with cross- functional discipline including PFDs, P&IDs, and material take-offs for the SRU project, achieving first-pass client approval and reducing rework during engineering reviews.
• Performed sulfur plant thermal and flow analyses that identified opportunities to minimize hydrogen sulfide carryover, improving catalyst life and reducing unplanned downtime by an estimated 15–20%.
• Prepared equipment datasheets, relief system evaluations, and safety documentation for Claus and Tail-Gas Treating sections, supporting HAZOP sessions and enhancing overall safety compliance.
• Collaborated with procurement team to secure long-lead SRU package units valued at $4M+, ensuring design compliance with client specifications and project schedule constraints.

Greenfield Hydrotreating & Solvent Deasphalting Complex – FEED & Detailed Engineering (OSBL Support)

• Led FEED and detailed engineering for the 40,000 BPD greenfield hydrotreating and solvent deasphalting complex, including OSBL utilities, storage, and offsite piping systems, ensuring full integration with the process units
• Developed comprehensive engineering package: heat & material balances, PFDs/P&IDs, equipment sizing, hydraulic calculations, and control narratives, supporting EPC execution and CAPEX accuracy within ±10%
• Defined OSBL utility requirements (steam, cooling water, fuel gas, flare, hydrogen, and nitrogen), sizing major pumps, compressors, tanks, and piping to ensure sufficient capacity for steady-state and contingency operations
• Coordinated multi-discipline engineering for OSBL interfaces, including civil, piping, instrumentation, and electrical, ensuring compliance with API, ASME, OSHA, and environmental regulations
• Supported HAZOP and design reviews for both process and OSBL systems, identifying and mitigating operational and safety risks before EPC award

• Collaborated with senior process engineers to develop process engineering deliverables, including preliminary design, heat and material balance, process simulation using ASPEN HYSYS, PFD, P&IDs, equipment sizing, and process data sheets for the dew point control unit project aimed at recovering NGL at Mellitah Oil & Gas B.V., adhering to ASME, ANSI, API, and other relevant standards.
• Prepared the Block Flow Diagram (BFD) and Process Flow Diagram (PFD).
• Conducted hydraulic studies and prepared engineering documents for modifications and de-bottlenecking efforts to maximize gas and condensate output.
• Supported the engineering side for skid-Package activities, including the installation of a new stabilization unit and two station Gas supply compressor package.
• Communicated with Kawasaki Japanese vendors to quote and purchase a cold box heat exchanger for the NGL plant, successfully negotiating to reduce project OPEX.
• Attended Process Safety and HAZOP studies for Engineering design Project.
• Estimating the Utility Duty specification of the Utility System.