Each case study below represents a real client engagement — a defined problem, a methodical engineering approach, and a quantifiable outcome. Names have been anonymised where required by confidentiality agreements, but the engineering details and business results are authentic.
Dr. Yadav's engagements span start-up advisory, operational troubleshooting, regulatory compliance, and strategic decarbonisation planning. The common thread is a commitment to evidence-based engineering that generates lasting commercial and environmental value.
Filter by engineering domain to explore how Dr. Yadav has solved complex challenges across industries.
A north-Indian refinery was experiencing declining LPG and propylene yields from its FCC unit due to an ageing catalyst formulation that was not optimised for its evolving crude slate — increasingly heavy, high-metals feedstock sourced from Middle Eastern sour crudes.
Conducted a full feedstock characterisation, equilibrium catalyst analysis (ECAT metals mapping), and benchmarked 6 commercial catalyst candidates using a laboratory MAT unit. Developed a blending strategy to manage transition without a unit shutdown, combined with additive injection to suppress SOx and improve bottoms cracking.
A fertilizer manufacturer sought to partially decarbonise its ammonia synthesis feedstock by integrating a dedicated green hydrogen plant powered by captive solar. The client had no prior experience with PEM electrolysis and needed a bankable pre-FEED report to approach lenders.
Evaluated three electrolyser technologies (PEM, alkaline, SOEC) against site-specific parameters including water quality, grid backup requirements, and thermal integration with the existing ammonia plant. Developed a full mass & energy balance, equipment list, CAPEX/OPEX model, and LCOH sensitivity analysis tied to solar tariff forecasts through 2035.
An ethylene cracker operating at 650 KTA was constrained 8% below nameplate capacity. The client's engineering team had attributed this to compressor limitations, but plant economics made a capital expansion unattractive in the near term.
Performed a systematic bottleneck mapping using process simulation (HYSYS) cross-validated with field DCS data. Identified the true constraint — a heat-exchanger fouling cycle in the quench water system — not the compressor. Implemented an optimised chemical treatment programme and adjusted cracking severity set-points for different feed slates.
A mid-size speciality chemicals manufacturer faced growing ESG scrutiny from its European export customers demanding credible decarbonisation commitments. The company had no baseline GHG inventory and no in-house capability to develop one to GHG Protocol standards.
Completed a full ISO 14064-1 / GHG Protocol-aligned Scope 1 and Scope 2 inventory across 3 manufacturing sites. Identified energy-intensive operations, developed a Material Energy Balance for each plant, and co-created a 5-year decarbonisation roadmap prioritising quick-win energy efficiency, fuel-switching, and RE procurement through RECs/PPAs.
An ammonia plant's primary reformer tubes were exhibiting elevated methane slip, high tube-wall temperatures, and reduced run-length compared to design. An early catalyst replacement would cost ₹12 Cr and require a 21-day planned shutdown.
Conducted wall-temperature profiling, post-sample catalyst characterisation (BET surface area, XRD, SEM), and sulphur adsorption mapping across the tube bundle. Root cause identified as localised feed-gas maldistribution causing hot-band formation. Proposed pigtail replacement in affected zones and operational set-point adjustments — avoiding the full reload.
A state government transport corporation exploring hydrogen fuel-cell buses needed an independent feasibility study to evaluate whether on-site green hydrogen production and dispensing was commercially viable for a 200-bus depot, and what the total cost of ownership looked like versus diesel and CNG alternatives.
Designed a 2.5 MW alkaline electrolyser system with tube trailer delivery backup, 700-bar cascade compression, and a dual-hose dispenser layout for high-throughput fuelling. Modelled daily hydrogen demand, electrolyser duty cycles, storage buffer, and grid interaction. Compared NPV, TCO, and carbon intensity against diesel fleet baseline over 15 years.