Mustafa Karakaya
Deerfield
Summary
Ph.D. chemical engineer with extensive R&D, reaction engineering, and process technology expertise, skilled at directing complex engineering programs from early innovation to full-scale commercialization. Experienced in aligning technical development with strategic business objectives, resolving complex customer challenges, and driving cross-functional collaboration. Proven track record of scaling novel technologies, optimizing operational performance, and delivering high-value solutions by leveraging advanced experimental and computational methods from lab to commercial scale.
Overview
15
15
years of professional experience
Work History
Director of Modeling, Catalysis and Downstream – Office of the CTO
LanzaTech Global
05.2024 - Current
- Coordinate product and technology development and operations support for feedstock preparation and product valorization
- Spearheaded the rWGS (reverse Water Gas Shift) development program, directing the technology lifecycle from bench-top catalyst screening to demonstration scale.
- Bench-Scale (1 kg/h CO2+H2): Designed the screening unit for stability and contaminant testing; served as the primary technical authority for all operational sign-offs and Management of Change (MoC).
- Intermediate Pilot (40 kg/h): Specified dual-reactor sizing, materials of construction (MoC) for HTHP syngas service, and the separation train for a modular system constructed by Parr; remotely commanded operations from the research facility. Worked with HSE for the HazOp and PSSR.
- Demonstration Scale (300 kg/h): Directed a "proof of concept" program at a customer site; engineered the repurposing of existing reactors and feed trains to achieve higher temperatures, successfully validating kinetic and phenomenological models. Worked with site HSE for the HazOp and PSSR.
- Directed engineering for the Gas Treating Apparatus (GTA), a truck-scale mobile pilot plant for on-site gas cleanup (removal of sulfur, oxygen, halogens, soot) and compression.
- Led specifications for reactor sizing, catalyst/adsorbent selection, hydrodynamic design, automation, and safety systems for varying hazardous environments.
- Lead portfolio of technology delivery projects with combined budget of $10M+
- Direct team of 7 specialists, fostering a collaborative, high-performance environment with ongoing training and professional development
- Develop and implement standardized project delivery methodologies resulting in 15% improvement in milestone achievement
- Implement value engineering ideas resulting in >10% reduction in CapEx
- Engage with internal and external stakeholders to ensure transparency and alignment with company objectives
Director of Catalytic Modeling – Technology & Manufacturing
LanzaTech Global
09.2021 - 05.2024
- Oversaw process and reactor/kinetic modeling activities with focus on catalytic conversion units
- Managed technical development schedule for multiple process subsystems
- Developed integration strategies between the proprietary LanzaTech process and subsystems upstream and downstream
- Led team of 2 direct reports while coordinating activities with 15+ scientists and engineers
- Implemented risk assessment protocol that identified and mitigated 8 major scale-up challenges
Lead Research Engineer – Gasification Group
Air Products and Chemicals, Inc.
05.2021 - 09.2021
- Led assessment of coal & biomass gasification technologies and offering development
- Managed project timelines and technical deliverables for technology evaluation
- Coordinated activities across research, engineering, and commercial teams
- Supported stakeholder presentations and updates to senior management
Principal Engineer – Engineering Design & Development
LanzaTech Global
03.2018 - 04.2021
- Served as technical lead in the scaling up and commercialization of the LanzaTech Alcohol-to-Jet process
- Managed generation and compilation of lab and pilot plant data for scale-up decisions
- Developed and maintained scalable process models for commercial deployment
- Generated PFDs, H&MB, P&IDs and utilities specifications for basic engineering design package
- Established and maintained relationships with EPC contractors for ISBL and OSBL FEED and detailed engineering, ensuring compliance with HSE and PSM regulations
- Coordinated complex interdependencies between process subsystems during design phase
- Implemented the stage-gate process to ensure technical readiness before advancing to next development phase
Senior Modeling Engineer – Process Modeling & Simulation Section
ADNOC Refining Research Centre, Abu Dhabi National Oil Company
01.2015 - 03.2018
- Senior role in group responsible for all process modeling and simulation activities across ADNOC Refining
- Developed process models for complex refinery units (Hydroprocessing, RFCC, Delayed Coker, ISOM)
- Designed and executed pilot plant experiments for kinetics development and scale-down
- Executed scale-down of refinery RFCC and hydrocracking processes to ensure “fit-for-purpose” representation on ACE and Xytel dual-reactor pilot plants, respectively.
- Developed high-fidelity digital twins with embedded kinetics using multiple discrete lumping (RFCC) and continuous lumping (hydrocracking) to facilitate future catalyst selection and process optimization activities.
- Coordinated 24/7 testing and analytics with the Pilot Plant and Analytical R&D departments; determined bed sizing and process specifications (B) to ensure pilot setup accurately mimicked commercial refinery unit design and operation.
- Conducted techno-economic and feasibility studies for process integration and energy optimization
- Provided support to flow assurance and reliability projects through simulation
- Managed technical delivery of multiple refinery improvement projects simultaneously
- Coordinated activities between research center and operational units during implementation to ensure best practices in process optimization and HSE management
R&D Scientist and Superintendent – Process Development Department
R&D Center, TÜPRAS (Turkish Petroleum Refineries Co.)
07.2012 - 10.2014
- Led Process Modeling & Simulation team, overseeing professional development and coaching of 8 engineers
- Directed technical selection for a HTHP hydroprocessing/hydrocracking pilot plant (2 kg/h heavy oil); managed the technical specification process internally. Led discussions with Vinci Technologies and also Xytel during the RFP.
- Utilized two-phase 1-D and 2-D reactor modeling to determine optimal catalyst volumes and the reactor line-up sequence for high-precision catalyst screening.
- Managed delivery of multiple process improvement projects for four TUPRAS refineries
- Coordinated implementation of new technologies (Delayed Coker) with refinery operations teams
- Developed and implemented project scheduling and tracking systems for R&D activities
Research Associate
R&D Center, TÜPRAS (Turkish Petroleum Refineries Co.)
09.2010 - 06.2012
- Conducted modeling & simulation of crude oil processing operations in TUPRAS Izmit refinery
- Contributed to technology assessment and selection for major refinery upgrade projects
Education
Ph.D. - Chemical Engineering
Bogaziçi University
Istanbul, Turkey06.2012
M.Sc. - Chemical Engineering
Bogaziçi University
Istanbul, Turkey02.2006
B.Sc. - Chemical Engineering
Bogaziçi University
Istanbul, Turkey07.2003
Skills
- Modeling & Simulation: gPROMS, Aspen Custom Modeler, MATLAB, Simulink, Aspen HYSYS
- Engineering Software: ANSYS FLUENT, COMSOL Multiphysics
- Programming: Python, Excel VBA
- Analytical: GC, GC-MS, FT-IR
- Automation: Allen-Bradley, Honeywell PLC
- Project Management Tools: MS Project, Stage-gate methodology
- Regulatory & Quality Systems: Familiarity with ISO 90001, OSHA, REACH, SEVESO Directive
Core Competencies
- Process Scale-up & System Integration
- Process Chemistry & Reaction Engineering
- Pilot Plant Design, Operations and Management of Change
- Process Hazard Analysis & HazOp
- Custom Process Modeling & Simulation
- Design of Experiments
- Process Intensification
- Design of Efficient Process Separations
- Technology Due Diligence
- Engineering Program Management
PUBLICATIONS
- Patents: US20250215459A1 – Flexible fermentation platform for improved conversion of carbon dioxide into products (pending)
- Journal Publications:
- Firmansyah, T., Rakib, M.A., Karakaya, M., AL Musharfy, M., Suleiman, M.I., “Mitigating flow induced vibration in heater radiant coil”, Oil & Gas Science and Technology, 73 (2018) 1-11.
- Karakaya, M., Rakib, M.A., AL Musharfy, M., Suleiman, M.I., “Simulation for prevention of hydrates during FCC-cracked gas processing”, Hydrocarbon Processing, April (2017) 47-52.
- Temur, T., Avcilar, S., Özünan, E., Karakaya, M., “Reduce LPG sulfur with a ‘rules of thumb’ checklist”, Gas Processing, June (2014) 35-38.
- Karakaya, M., Önsan, Z.I., Avci, A.K., “Microchannel autothermal reforming of methane to synthesis gas”, Topics in Catalysis, 56 (2013) 1716-1723.
- Temur, T., Haktanır, M., Uzman, F., Karakaya, M., Avci, A.K., “Optimize vacuum ejector operations”, Hydrocarbon Processing, May (2013) 99-102.
- Simsek, E., Karakaya, M., Avci A.K., Önsan, Z.I., “Oxidative steam reforming of methane to synthesis gas in microchannel reactors”, International Journal of Hydrogen Energy, 38 (2013) 870-878.
- Hosukoglu, I., Karakaya, M., Avci, A.K., “Modeling and simulation of hydrocracking of Fischer-Tropsch hydrocarbons”, Industrial & Engineering Chemistry Research, 51 (2012) 8913-8921.
- Karakaya, M., Keskin, S., Avci, A.K., “Parametric study of methane steam reforming to syngas in a catalytic microchannel reactor”, Applied Catalysis A: General, 411-412 (2012) 114-122.
- Karakaya, M., Avci, A.K., “Microchannel reactor modeling for combustion driven reforming of iso-octane”, International Journal of Hydrogen Energy, 36 (2011) 6569-6577.
- Avci, A.K., Trimm, D.L., Karakaya, M., “Microreactor catalytic combustion for chemicals processing”, Catalysis Today, 155 (2010) 66-74.
- Karakaya, M., Avci, A.K., “Comparison of compact reformer configurations for on-board fuel processing”, International Journal of Hydrogen Energy, 35 (2010) 2305-2316.
- Karakaya, M., Avci, A.K., “Simulation of on-board fuel conversion in catalytic microchannel reactor-heat exchanger systems”, Topics in Catalysis, 52 (2009) 2112-2116.
- Aktas, S., Karakaya, M., Avci, A.K., “Thermodynamic analysis of steam assisted conversions of bio-oil components to synthesis gas”, International Journal of Hydrogen Energy, 34 (2009) 1752-1759.
- Karakaya, M., Avci, A.K., Aksoylu, A.E., Önsan, Z.I., “Steady state and dynamic modeling of indirect partial oxidation of methane in a wall-coated microchannel”, Catalysis Today, 139 (2009) 312-321.
- Öritçi, E., Karakaya, M., Avci, A.K., Önsan, Z.I., “Investigation of ethanol conversion for hydrogen fuel cells using computer simulations”, Journal of Chemical Technology & Biotechnology, 80 (2005) 1103-1110.
- International Conferences:
- Rakib, M.A., Karakaya, M., Singaravel, G., Al Katheeri, A.M., Basheer, S., AL Musharfy, M., Suleiman, M.I., Spetanak, S., “Kinetics study and its implementation in a first principles model for the riser of a Resid Fluid Catalytic Cracking Unit”, 8th World Congress on Particle Technology, 22–26 April 2018, Orlando, Florida, USA. (Oral)
- Al Katheeri, A.M., Singaravel, G., Rakib, M.A., Karakaya, M., Morin, S., AL Musharfy, M., Suleiman, M.I., Berthod, M., “Kinetics of Resid Fluid Catalytic Cracking using a laboratory reactor”, AIChE 2017 Annual Meeting, 29 October–3 November 2017, Minneapolis, Minnesota, USA. (Poster)
- Karakaya, M., Rakib, M.A., AL Musharfy, M., Suleiman, M.I., “Analysis of gas hydrates formation in an Ethylene Recovery Unit”, 7th ARRC–JCCP/Idemitsu Refining R&D International Symposium, 25–27 September 2017, Abu Dhabi, United Arab Emirates. (Oral)
- Karakaya, M., Rakib, M.A., AL Musharfy, M., Suleiman, M.I., “Modeling and simulation for flow assurance in FCC-cracked gas processing”, AIChE 2017 Spring Meeting, 26–30 March 2017, San Antonio, Texas, USA. (Oral)
- Suleiman, M.I., Rakib, M.A., Kelani, H., Karakaya, M., Ahmed, R., AL Musharfy, M., “Development of predictive model for sulphur species thermal dissociation and related conversion in condensate feedstock”, EUROCORR 2016 – The European Corrosion Congress 2016, 11–15 September 2016, Montpellier, France. (Oral)
- Rakib, M.A., Karakaya, M., Umar, S.B., Singaravel, G., Taher, A., AL Musharfy, M., Spetanak, S., Aguerrereze, J., “Modelling an integrated RFCC unit with a secondary riser”, CHISA 2016 – 22nd International Congress of Chemical and Process Engineering, 27–31 August 2016, Prague, Czech Republic. (Poster)
- Karakaya, M., Taher, A., Rakib, M.A., Dakhan, M.A., Hussain, M.Y., Al Hamadi, A., “Development of a predictive model for the thermal dissociation of sulphur species developed using data from a pilot plant imitating the commercial operation”, ISCRE 24 – 24th International Symposium on Chemical Reaction Engineering, 12–15 June 2016, Minneapolis, Minnesota, USA. (Oral)
- Karakaya, M., Taher, A., Rakib, M.A., “Modeling and simulation of heavy oil hydrocracking using the continuous lumping approach”, 6th ARRC–JCCP/Idemitsu International Symposium, 10–11 February 2016, Abu Dhabi, United Arab Emirates. (Oral)
- Karakaya, M., Rakib, M.A., Rana, S.Z., “Model development of a light naphtha isomerization unit”, 6th TRC–JCCP/Idemitsu International Symposium, 10–11 February 2016, Abu Dhabi, United Arab Emirates. (Poster)
- Fidan, H., Önsan, Z.I., Avci, A.K., Karakaya, M., “Modeling and analysis of a commercial isomerization reactor”, AIChE 2013 Annual Meeting, 3–8 November 2013, San Francisco, California, USA. (Poster)
- Karakaya, M., Avci, A.K., “Microchannel methane-to-syngas conversion over alternative catalyst configurations”, NGCS-10 – 10th Natural Gas Conversion Symposium, 2–7 March 2013, Doha, Qatar. (Oral)
- Karakaya, M., Avci, A.K., “Simulation and testing of syngas production in a heat-exchange integrated microchannel reactor”, ISCRE 22 – 22nd International Symposium on Chemical Reaction Engineering, 2–5 September 2012, Maastricht, The Netherlands. (Oral)
- Karakaya, M., Simsek, E., Avci, A.K., Önsan, Z.I., “Oxidative steam reforming of methane in microchannel reactors”, ISCRE 22 – 22nd International Symposium on Chemical Reaction Engineering, 2–5 September 2012, Maastricht, The Netherlands. (Oral)
- Sen, I., Karakaya, M., Avci, A.K., “CFD simulation of exhaust gas reforming of propane in a heat exchange integrated microchannel reactor”, CAPoC 9, 9th International Congress on Catalysis and Automotive Pollution Control, 29–31 August 2012, Brussels, Belgium. (Poster)
- Karakaya, M., Simsek, E., Önsan, Z.I., Avci, A.K., “Microchannel catalyst configurations for oxidative steam reforming of methane to syngas”, ICC 15 – 15th International Congress on Catalysis, 1–6 July 2012, Munich, Germany. (Poster)
- Karakaya, M., Avci, A.K., “Experimental investigation of syngas production by oxidative steam reforming of methane in a microchannel reactor”, IMRET 12 – 12th International Conference on Microreaction Technology, 20–22 February 2011, Lyon, France. (Poster)
- Karakaya, M., Avci, A.K., “Experimental investigation of syngas production by methane steam reforming in a microchannel reactor”, Energy and Materials from the Sun – Summer School, 20–23 June 2011, Kerkrade, The Netherlands. (Oral) Awarded with the EFCATS Scholarship
- Karakaya, M., Avci, A.K., “Synthesis gas production by methane steam reforming in a catalytic microchannel reactor”, CAMURE-8 – Catalysis in Multiphase Reactors, 22–25 May 2011, Naantali, Finland. (Poster)
- Kircin, R.M., Karakaya, M., Avci, A.K., Aksoylu, A.E., Önsan, Z.I., “Modeling of a catalytic plate reactor producing hydrogen for fuel processor systems”, CHEMREACTOR-19 – 19th International Conference on Chemical Reactors, 5–9 September 2010, Vienna, Austria. (Poster)
- Karakaya, M., Avci, A.K., “Modeling of catalytic microreactors for naphtha steam reforming”, CHEMREACTOR-19 – 19th International Conference on Chemical Reactors, 5–9 September 2010, Vienna, Austria. (Poster)
- Gümüstü, G., Karakaya, M., Avci, A.K., “Parametric study of the Fischer-Tropsch synthesis in catalytic microchannels”, NGCS-9 – 9th Natural Gas Conversion Symposium, 30 May–4 June 2010, Lyon, France. (Poster)
- Karakaya, M., Avci, A.K., “Comparison of two compact reactor systems for hydrogen production”, IMRET 11 – 11th International Conference on Microreaction Technology, 8–10 March 2010, Stuttgart, Germany. (Poster)
- Karakaya, M., Avci, A.K., “Microchannel reactor modeling and design for catalytic hydrocarbon steam reforming”, AIChE 2009 Annual Meeting, 8–13 November 2009, Nashville, Tennessee, USA. (Oral)
- Karakaya, M., Avci, A.K., “Simulation of on-board fuel conversion in catalytic microchannel reactor-heat exchanger systems”, CAPoC 8, 8th International Congress on Catalysis and Automotive Pollution Control, 15–17 April 2009, Brussels, Belgium. (Poster)
- Talay, G., Karakaya, M., Avci, A.K., “Design and optimization of micro reactor-heat exchanger cascade configurations for autothermal conversion of iso-octane to hydrogen”, AIChE 2008 Annual Meeting, 16–21 November 2008, Philadelphia, Pennsylvania, USA. (Oral)
- Karakaya, M., Avci, A.K., Aksoylu, A.E., Önsan, Z.I., “Dynamic simulation of an indirect partial oxidation reactor for methane conversion to hydrogen”, Fuel Cells Science and Technology 2006 - Scientific Advances in Fuel Cell Systems, 13–14 September 2006, Torino, Italy. (Poster)
- Orucu, E., Karakaya, M., Avci, A.K., Önsan, Z.I., “Investigation of ethanol conversion for hydrogen fuel cells using computer simulations”, ICC 13 – 13th International Congress on Catalysis, 11-16 July 2004, Paris, France. (Poster)
PROFESSIONAL DEVELOPMENT
- PMP Certification – Application accepted by PMI, exam pending
- Lean Six Sigma Training – in progress
- Real Time Optimization (RTO) Workshop by Shell Global Solutions (2014)
- Hydroprocessing, Hydrocracking and Reforming Catalysts Training by Axens (2015)
- Criterion – Shell Technical Workshop (2016)
- UOP – ADNOC Refining Workshop (2016)
- Design of Experiments (DoE) Training by STATCON (2016)
Timeline
Director of Modeling, Catalysis and Downstream – Office of the CTO
LanzaTech Global
05.2024 - Current
Director of Catalytic Modeling – Technology & Manufacturing
LanzaTech Global
09.2021 - 05.2024
Lead Research Engineer – Gasification Group
Air Products and Chemicals, Inc.
05.2021 - 09.2021
Principal Engineer – Engineering Design & Development
LanzaTech Global
03.2018 - 04.2021
Senior Modeling Engineer – Process Modeling & Simulation Section
ADNOC Refining Research Centre, Abu Dhabi National Oil Company
01.2015 - 03.2018
R&D Scientist and Superintendent – Process Development Department
R&D Center, TÜPRAS (Turkish Petroleum Refineries Co.)
07.2012 - 10.2014
Research Associate
R&D Center, TÜPRAS (Turkish Petroleum Refineries Co.)
09.2010 - 06.2012
M.Sc. - Chemical Engineering
Bogaziçi University
B.Sc. - Chemical Engineering
Bogaziçi University
Ph.D. - Chemical Engineering
Bogaziçi University