Madeswaran SASITHARAN

Filed patent for continuous hydrogenation process development in FBR and minimized COGS from $29 to $21.

Worked on CAPEX estimation and design concepts for commercial scale for 120 MT per annum capacity.

Developed a continuous process for an API molecule with three steps methylation, photochlorination, and fluorination.

Performed CoGs assessment and devised a proactive strategy to lower cogs in photochlorination development step itself

Developing continuous fractionating column for high-purity isolation with sulzer team

Leading a team in executing multiple flow chemistry projects with timely developing the POC, DHR filing and scaleup.

• Designed fixed bed flow reactor, scaledup from lab to commercial levels with DCS logic for 50 MT capacity.
• Developed proof of concept for photochlorination project, successfully scaled up from lab.
• Coordinated HAZOP study with DEKHRA consultant for safe handling of ethylene oxide gas.
• Tech transferred and delivered two CRO molecules from lab scale to commercial scale within established timelines.
• Performed a PRA report for each molecule and implement a advance level safety for the process.

• Scaled-up a liquid liquid extraction using PCTR with 150 lph throughput and reduced the solvent washing cycles.
• Scaled-up a continuous crystallization by using PFC with throughput of 270 lph and reduced cycle time by 16 hrs to 2 hrs.
• Handled and worked on various process feasibility studies involving Micro reactors, PCTR, ACE, Nano filtration, and ATF with full automation.

• Worked on various process intensification technologies, including continuos extraction, distillation, and mechanization in a multi product DCS facility.
• Commissioned a 600 LPH Rotating Disc Contactor for continuous extraction, integrating it with DCS systems for real-time monitoring and control.
• Automated critical unit operations, including reaction, filtration, and drying, using Emerson Delta-V and Siemens PCS7 DCS systems.
• Conducted SWFAT for equipment modules and safety interlocks, ensuring compliance with regulatory standards.

• Prepared Basic and detailed engineering proposals with capacities ranging from 60-100 TPM
• Prepared material balance, energy balance, utility calculation, and solvent recoveries for APIs, and prepared RFPs for CRAMS products.
• Performed condenser adequacy calculations and calculated the utility requirements for the solvent recovery plant and in-process distillation for the overall site.
• Performed PHA, HAZOP, and other safety studies and documentation.