Dynamic Simulation & Real-Time Optimization (RTO) Consultant

Position Summary

We are seeking a highly motivated and experienced Dynamic Simulation & Real-Time Optimization (RTO) Consultant to join our team. The role will focus on improving refinery profitability, operational reliability, energy efficiency, and process performance by leveraging first-principles models, dynamic simulation technologies, plant data, and advanced optimisation techniques.

Key Responsibilities

Dynamic Process Simulation

- Develop, validate, and maintain dynamic simulation models for refinery units such as CDU, VDU, FCC, Hydrocracker, Reformer, Delayed Coker, Hydrotreaters, Utilities, and Offsites.
- Perform startup, shutdown, upset, debottlenecking, and controllability studies using dynamic simulation platforms.
- Model process equipment including reactors, columns, heat exchangers, compressors, furnaces, pumps, and utility systems.
- Support operator training simulators (OTS) and digital twin initiatives.

Real-Time Optimization (RTO)

- Design and implement refinery RTO applications to maximize profitability, throughput, yield, and energy efficiency.
- Develop optimisation strategies considering process constraints, product specifications, inventory targets, and economic objectives.
- Conduct what-if scenario analysis and recommend optimal operating strategies.
- Monitor optimisation results and continuously refine models to improve accuracy and business value.

Digital Twin & Data Integration





- Build digital twin solutions enabling real-time performance monitoring and operational decision support.
- Support deployment of advanced analytics and AI/ML-enabled optimisation initiatives.

Continuous Improvement

- Establish KPIs for model performance and optimisation effectiveness.
- Identify opportunities to improve refinery profitability, energy consumption, product quality, and operational reliability.
- Develop technical documentation, operating procedures, and user training materials.

Required Qualifications

- Bachelor's or Master's degree in Chemical Engineering
- 8+ years of refinery process engineering, simulation, or real time optimisation experience.
- Robust understanding of refinery processes, thermodynamics, reaction engineering, heat transfer, and process control.

Technical Skills

Process Simulation Software

Experience with one or more of:

- Aspen HYSYS Dynamics
- Aspen Plus
- PetroSIM
- UniSim Design / Dynamics
- PRO/II
- DWSIM

Real-Time Optimization & Advanced Applications

Experience with

- Aspen DMC3 / APC environments
- Aspen Online
- Aspen GDOT / RTO
- Honeywell Profit Suite
- KBC Technologies solutions
- Digital Twin platforms

Preferred Industry Experience

- Oil & Gas Refining
- Petrochemicals
- Integrated Refining & Petrochemical Complexes
- Digital Twin / Smart Manufacturing Programs
- Advanced Process Control and Optimisation Projects

📌 Dynamic Process Simulation & RTO Consultant (Hyderabad)
🏢 Proclink
📍 Hyderabad